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American Power Conversion MX28B4800 User's Manual

1. LY DATE OUT RLY Date E gt OUTSREY SDN RLY MAP ALIAS Qub RIV X Alm E e Tr Tessa TT fornynmn TT Tosse e o fornysun i Te fornysmn Oe Ry og Oe Ry Ee EEN O RS O E TT Toso TT fornysm TL J n Jenni O AP ALIAS Out Rly 1 1 71 5 Ou A MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 47 e le amyd i EE EEN OE army OE osx e ICE GER SE EG LY IN RLY DIAG RLY MAP ALIAS In RIv JX A T EIEN AP ALIAS In Rly 1 CSS pene ems ema O Lamp tes Test Relay En LY DIAG Test Relay 6 Test Min Rly S MX28B 1200 M MOD REC EM MODULES BATT RECT CLR BRR SET ALM PARAM I Rect CL Alm Rect Stdby Alm 5d E OD MODs REC LM PARAM INFO Rect Fail Safe MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 48 Top Level Second Level Third Level Fourth Level Ps Reet Fasi Comm MOD REC AM INFO Rect Desc Rect CL Rect Stdby CT CER BRR FUSE SET ALM ALIAS Cir Bkr 1 Alm Cae Bkr 7b ol CIE BKE BE ATM MOD CIR LM ALIAS Cir Bkr q Oit ie 70 MOD F MOD CT Oit BKE 72 MOD 35 MOD FEU S F KR FUSE LYD SET ALM ALIAS FUSE 1 Alm FUSE 4 Alm MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 49 op Level Second Level Third Level Fourth Level ot FUSE 6 Atm ot FUSE 7 Aim ot FUSE 9 Atm ot FUSE 9 Atm 7 rose 10am rose nam 7 rose 12am 7 rose 13am 7 rose main 7 rose 25am i FUSE 16Alm MOD BF Bu LM ALIAS F
2. DESCRIPTION DISPLAY SCREENS DEFAULT SETTINGS Power plant address or identification first line Address 1 m APC DENS ING Power plant address or identification second line Address 2 m LO 3 5 Swat Zer AW Power plant address or identification third line Address 3 m Dallas TX Display of up to 16 active alarms a typical alarm Alarm Item 1 screen is shown Batt LV Alm Onm Display of up to 16 active alarms a typical alarm Alarm Item 16 screen is shown No Alarms Battery current measured by the system controller Batt Current at the battery current shunt zoo A The output relay energized if the battery discharge Batt Disc Alm m current exceeds the programmed battery Minor discharge threshold An alarm is generated if the battery discharge KO A current exceeds this value Batt Float m a Ug VY One of three parameters that control the DC output voltage Set the Float Voltage at 25 C battery temperature per the battery manufacturers recommendations Page 3 PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Battery High Temperature The output relay energized if the battery Batt HT Alm m Alarm temperature exceeds the Battery High Minor Security Level 1 Temperature threshold BATT SET ALM Battery High Temperature Battery Temperature is temperature measured at Batt HT Thr m Threshold the battery probe An alarm is generated if the hoa we Securi
3. System Current The PSCU monitors individual rectifier currents and displays total system current as a sum of rectifier currents Load current can be found by adding battery current to system current Battery Current is positive when the battery is discharging Sys Current Batt current Load Current For example if the battery is charging the Batt Current reading could be 40 A Sys Current reading could be 120 A Load Current would be Sys Current Batt current Load Current 120A 40 A 80 Amps If the battery is discharging the Batt Current reading would be 40 A Sys Current would reading would be 40 A Load voltage would be Sys Current Batt current Load Current 40A 40 A 80 Amps MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 33 System Status and Alarm Reporting The PSCU monitors system voltage using a high accuracy digital voltmeter attached to the system bus The PSCU monitors system temperature using a temperature IC mounted in the PSCU The PSCU monitors system current by summing the current reported by individual rectifiers The PSCU reports a number of system alarms including system high low voltage and high low temperature Refer to Section 5 6 for PSCU control functions 5 4 DC Distribution Distribution is included in each bay for up to 48 plug in circuit breakers a variety of bolt in breaker sizes or four telecom fuses Circuit breaker bays with three rows of bolt in circuit breakers
4. The DB9 connector on the top right hand side of the unit behind a blank panel directly above the controller uses the special RS 232 cable APC part number 940 0024C to allow local access through a Terminal Emulation program like HyperTerminal or Procomm RJ45 Ethernet Connector The optional management card which is behind a blank panel directly above the controller has an RJ 45 connector to support a TCP IP protocol over a 10BaseT Ethernet Local Area Network LAN Relay Output Connections There are eight alarms available that provide outputs via Form C relay contacts The last two of these are pre assigned as the Minor and Major relay outputs The Major relay is energized NO C contacts closed during normal non alarm operating conditions all the other relays energize when an alarm condition occurs The other six outputs are initially designated as Relay 1 through Relay 6 the user may assign more meaningful names if desired The various system alarm conditions can be assigned to any of the eight alarm outputs There are three sets of Wago connectors on the interface card Two are for Output Relays and one is for Input Relays To attach the Output Relay wires push down on the white spring loaded lever Insert the wire and release the lever Refer to the board layout in Figure 3 9 1 for Output Relay connections The relay contacts should only be used to switch resistive loads of 0 5 amperes or less at 60 volts or less
5. www apc com MX29B1200 2400 MX28B1200 4800 48 VDC POWER SYSTEMS Users Manual Documen t 990 1148A Table of Contents 1 SAFETY oy pod KEE 1 Vets E leed Te EE 1 1 2 GENERAL PEEGAUTIONS liu clericali 1 2 INTRODUC ON Dre 2 2 1 GENERAL INFORMATION E 2 2 2 HOW TO USE THIS MANUAL oie OD ee up ee ede ee ede ee ede ee Pe FERE EE ERGE EE OE Ee Ee 2 gt INSTALLATION sesse se YY e ov ek ed ee WY a gs be ge be eg EE 5 3 1 UNPACKING EQUIPMENT Ae 5 3 2 MECHANICAEINSTAEEATION EEN 5 ROOM LOC IUO GE E 5 MOUNUNG EE 6 Power BUS COICO OINS EE 6 Circuit Breaker L VD Ribbon Cable Connections e LLY GL GYG LL LL Y Y Y Y Y Y esee see 8 Fuse Alarm EIDDon Cable Connection Sm Y i Oddi 9 Veg 1 12 141912 EE 9 33 CPOWERCONNECTIONS ce GL ON CL UR Ge GR UU NO O COC LU 9 3 4 BATTERY CONNECTIONS eene enhn GL Y e Y LE ELE LANE LL LE LLE LEL LL ee ee ee CF ee A EFE re reis 11 Planne ne Bary ANSAN QUOI ue dei RE eate dae EB EUR DARO ANED 11 Connecung Ne Baler Cables uice i nd SS NON 12 3 0 DE SYSTEM GROUNDING en EG BEE Se Ge EE n DE menie RE RE teniente Ee GE GE ER EG EG Ee 13 3 6 DC POWER OUTPUT OVER CURRENT HROTECTION ee ee ee ee ee ee GG ee ee ee Y ee ee ee ee ee ee ed 14 DE Plud m Reeg ke ee HN RI HC RR GE Ie GE ee GE Ge GE coe ee 14 DC Bolt in Circuit i i ECT 17 POLO COMA EE 18 3 7 INSTALLATION OF CIRCUIT BREAKERS AND FUSES III memes nemen ens 19 Plug in Circuit Breaker Jnstallaton
6. PIN screen enables modification of all variable system parameters Security level 1 enter 1111 on the PIN screen permits modification of some parameters No security is required for viewing status items and parameter settings The security level password is entered through the PIN screen If no front panel keys are pressed for 60 minutes the active security level password reverts to level 0 and MAPCR begins to move about the display Pressing any key returns the display to normal and the password must be re entered if system parameters require changes Eleven LEDs are provided on the front panel of the control unit to indicate system status Three LEDs grouped together vertically provide overall system status they are MAJOR MINOR and NORMAL indicating the presence of a major alarm a minor alarm or normal operation The other eight LEDs correspond to the active state of each of the alarm output relays and are labeled ALM1 ee e ALM6 MIN and MAJ MX28B 1200 ar STATUS ALARMS SYSTEM MODULES BATT PIN OEM Figure 5 6 1 Menu Top Line Parameter Locations Descriptions and Default Values The location description and factory programmed default value for each of the MX28B system parameters is found in the table below The table also shows all of the status and information screens with typical displays The location of a parameter screen is shown in brackets for example SYSTEM IN RLY RLY MAP To find the para
7. these assignments are located at SYSTEM OUT RLY RLY MAP This feature makes it possible for a single alarm condition to activate multiple alarm output relays including the Minor or Major alarm relay A user defined name or alias may also be assigned to each of the eight output relay alarms Screens for making these assignments are located at SYSTEM OUT RLY ALIAS For information on making wiring connections to the alarm output relays refer to Section 3 9 MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 52 5 8 External Alarm Inputs Input Relays The controller can monitor any external device that uses a switch or relay to output status information Connecting the external device to the input relay connections is the first step The four external alarm inputs also referred to as Input Relay Alarms can be assigned a priority and routed or mapped to alarm output relays Available assignments are Ignore Major Minor and Relay 1 Relay 6 do not map relay to itself or the alarm will never clear screens for making the assignments are located at SYSTEM IN RLY RLY MAP A user defined name or alias may also be assigned to each of these input alarms Screens for making these assignments are located at SYSTEM IN RLY ALIAS For information on wiring connections to these inputs refer to Section 3 10 MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 53 6 Remote Monitoring
8. Fuse 13 16 Only one fuse can be hooked up to any alarm wire Refer to the following pictures for more information E Figure 3 6 5 Telecom Fuses MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 18 3 Installation of Circuit Breakers and Fuses Plug in Circuit Breaker Installation CAUTION During circuit breaker installation carefully align the breaker alarm terminals with the alarm terminal board to avoid breaker terminal damage 1 Remove the circuit breaker cover panel and the plastic cover s from the desired location s 2 Install the circuit breaker s by snapping the top terminal onto the upper bus bar and rotating the unit down until the second terminal snaps onto the breaker termination post as shown in Figure 3 7 1 The breaker alarm terminals are designed to make contact with the alarm terminal board as the breaker is snapped into place 3 Reattach the circuit breaker cover panel Figure 3 7 1 Installation of Circuit Breakers Page 19 MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Bolt in Circuit Breaker Installation 1 Remove the circuit breaker cover panel and the plastic cover s from the desired location s 2 Install the circuit breaker s by bolting the circuit breaker onto the bus at the bottom of the assembly Bolt the lug landing bus to the top of the breaker 3 Attach alarm wires to circuit breaker alarm outputs The wires should be attached to the co
9. Level 1 SYSTEM OUT RLY RLY MAP Output Relay 1 Alias Security Level 1 SYSTEM OUT RLY ALIAS Output Relay 6 Alias 1 SYSTEM OUT RLY ALIAS DESCRIPTION Must be set to Enable if the unit has an LVD If the unit has an LVD but it is disabled the controller will not disconnect the LVD LVD Reset reconnect threshold voltage LVD Trip disconnect threshold voltage The output relay that is energized when the controller opens the LVD If unit has a battery LVD no power will be available to turn on any Output Relays Model type number for the MX28B DC power plant Choose the MX28B 1200 if you have the 2500 Amp battery shunt Choose the MX28B 4800 if you have the 5000 Amp battery shunt NOTE Changing the model number causes the system to reinitialize Voltage gain adjustment for factory calibration of system voltage readings settings Voltage offset adjustment for factory calibration of system voltage readings settings Current gain adjustment for factory calibration of battery current readings settings Current offset adjustment for factory calibration of battery current readings settings Output Relay 1 Alarm can be mapped to activate other output relays Ignore activates no additional relays Output Relay 6 Alarm can be mapped to activate other output relays Ignore activates no additional relays An alternate name alias can be assigned to Output Relay 1 if desire
10. Lilli 63 Ob CON FEIC Ea 63 9 APC WORLDWIDE CUSTOMER SUPPORT esse ee ee ee sk ee ske eke eke ER ee ER ee SR EE ERGER Re Rea ER ee Re 64 10 LIMITED PRODUCT WARRANTY iii 65 MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page iv Revision History Revision Date By Description 31 JAN 2002 Converted to APC numbering 28 SEP 2003 Updated Format and added 4800 Table of Figures FIGURE 2 2 1 MX28B 1200 48 VDC POWER PLANT RECTIFIER BAY ere 3 FIGURE 2 2 ME SBBEOCK DIAGRAM ee 4 FIGURE 32 1 FLOOR MOUNTING DIMENSION S spears 6 FIGURE 3 2 2 MX28B 1200 2400 HAS A MAXIMUM CAPACITY OF 2400 AMPS 7 FIGURE 3 2 3 THE MX28B1200 4800 CAN BE EXPANDED TO 4800 AMPS sesse ee ee ee ee ee ee d FIGURE 3 2 4 SPLICE PLATE INSTALLATION E 7 FIGURE 3 2 5 CIRCUIT BREAKER LVD EXPANSION BOARD 8 FIGURE 3 2 6 WAGO FUSE ALARM BREAKOUT BOARD 9 FIGURE 3 521 AC TNPUT WIRING es see ee ese Ee es See Ge ee CAS a eg ee ie Gee EF iue Food 10 FIGURE 3 4 1 BATTERY CABLE CONNECTION LOC ATIONS ei Es soe ese Res pce bene ie bees 12 FIGURE 54 2 BATTERY BROBE CONNEC HON as ope es RR es eon cated es es ee On aa Rete 13 FIGURE 3 4 3 BATTERY PROBE INS TALE NEO NE iet Mense Ges ed ee eene Ee ee Dee spe ES Re ee 13 FIGURE 5 3 DE SY STEM GROUNDING un mE mA a DER DD ERU ED RM HO SUM Oe See Ee eek AA D Dee ee 14 FIGURE 35 3 BOX FRAME GROUND uu auth A De eed Ee
11. NOTE This information can be viewed for each rectifier installed by using the horizontal arrow keys A display of the DC output current for the individual rectifier NOTE This information can be viewed for each rectifier installed by using the horizontal arrow keys MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page 42 PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Rectifier Description Displays the model number of the installed Rect 1 Desc Status Only rectifier NOTE This information can be MRF28H54 MODULES RECT INFO viewed for each rectifier installed by using the horizontal arrow keys Rectifier Fail 1 of N Alarm The output relay energized if Rectifier Fail 1 of N Rect lofN Almm Security Level 1 alarm occurs This is a special rectifier alarm Minor SYSTEM SET ALM group that signifies that one rectifier has at least one alarm condition Rectifier Fail 2 of N Alarm The output relay energized if Rectifier Fail 2 of N Rect 2ofN Almm Security Level 1 alarm occurs This is a special rectifier alarm group Major SYSTEM SET ALM that signifies that more than one rectifier has at least one alarm condition Rectifier Fail Safe Voltage Rectifier default output voltage if communication Rect Fail Safemr Security Level 1 with the control unit fails BY D cw MODULES RECT PARAM Rectifier Fan Fail Alarm The output relay that is energized or special Rect FF Alm m Security Level 1 rectif
12. The following shows the alarm output connection designations CAN 48V RTN Figure 3 9 1 Interface Board MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 24 RELAY TERMINAL OUTPUT DESIGNATION USER ALARM NOTES NO NC C RELAY 1 NO1 NC1 C1 RELAY 2 NO2 NC2 C2 RELAY 3 NO3 NC3 C3 RELAY 4 NO4 NC4 C4 RELAY 5 NO5 NC5 C5 RELAY 6 NO6 NC6 C6 MINOR NO7 NC7 C7 MAJOR NO8 NC8 C8 Figure 3 9 2 Output Relay Connections 3 10 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 NO and common C or contact openings between normally closed NC and C External Alarm Source Connect To Input non alarm state Alarm Terminals OPEN NO C CLOSED NC C Figure 3 10 1 External Alarm Input Definition Connector J4 is located on the interface card mounted in the top left side of the unit Refer to Figure 3 9 1 for Interface board connections Systems are shipped with jumper wires connecting each NC and corresponding C contact A jumper wire should be removed only if the corresponding NC C contacts are going to be used To attach the Input Relay wires push down on the white spring loaded lever insert the wire and release the lever EXTERNAL J4 TERMINAL DESIGNATION USER ALARM NOTES NO1 NC1 C1 NO2 NC2 C2 NO3 NC3 C3 NO4 NC4 C4 Figure 3 10 2 External Alarm Input Connections M
13. current ranges 50 4800 amperes without special application engineering or assistance Distribution can be included for a variety of circuit breakers or Telecom style fuses These circuit breakers can be 1 to 700 amps Fuses can be 70 to 600 amps An optional low voltage disconnect LVD can be provided on either the battery or the load side A 1200 amp MX28B Rectifier Bay is shown in Figure 2 2 1 A block diagram is shown in Figure 2 2 2 2 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 Figure 2 2 1 MX28B 1200 48 VDC Power Plant Rectifier Bay Page 3 MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual LOAD CIRCUIT BREAKER SHELF RIGHT LOAD RETURN BUS BAR ANA 0968 POWER SYSTEM EE CONTROL UNIT ANA 0964 EAA 0004 TO DC DC CNVTR IN EXT BAY j ANA 0969 e ie a Tn SN wao TT a _ SHELF 1 13 y ih DC DC CNVTR O EAA 0111 2 lt r IT Jt DT EE kes SHELF CNTLR PCB RNA 0917 1 4 PER SHELF EAA 0062 Fe RECTIFIER SHELF 2 DEL ia RECTIFIER SHELF 3 A RECTIFIER a Ill SHE
14. hole lugs on load return wires MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page 22 Figure 3 8 1 Load connections for snap in PIWS OEI CONnocdone breakers GMT Fuse Connections GMT fuses are only connected to 48VDC if the system has been purchased with the GMT fuse option This option supplies 48VDC to lugs on the interface card through 6 AWG power cables controlled by a 50 Amp circuit breaker located in circuit breaker Position 1 The 2 hole lugs on both ends of the power cables have 10 holes on 5 8 centers Connections to the GMT fuses are made at terminal block connectors labeled F1 through F8 that are located on the interface card mounted in the top left side of the unit The connector is sized to accept 12 28 AWG wire Each connector has two positions labeled 48V and RTN for connection of the 48V DC load and load return wires Refer to Figure 3 9 1 for Interface board connections NOTE The controller will not report GMT Fuse failures in the MX28B1200 system Only telecom style fuses can be monitored Use GMT fuses only in non essential applications 3 9 Monitoring and Relay Output Connections Front Panel DB9 Connection The front panel DB 9 connector is for use by the factory only Do not hook up the special RS 232 cable APC part number 940 0024C This cable is only to be used with the DB 9 near the Web Simple Network Mail Protocol Web SNMP card Smart Cable DB9 Connection
15. or fuse bays are also available The plug in circuit breakers can be 1 to 100 amps with 60 100 amp breakers requiring two positions and a circuit breaker adapter kit When a plug in circuit breaker trips a normally open switch closes and a CB alarm is reported by the PSCU To disconnect a load attached to a circuit breaker move the lever to the down OFF position To disconnect a load attached to a telecom fuse pull the fuse holder straight out of the fuse holder base NOTE Plug in Circuit breaker alarm contacts close when the circuit breaker is tripped but not when it is turned OFF Bolt in Circuit breaker alarm contacts close when the circuit breaker is tripped or turned OFF 5 5 Battery Management Battery Charging and Protection Battery charging and protection are integrated into the MX28B DC power system to support the primary function of providing power to the load Accurate measurement of battery parameters like voltage current and temperature are used to maintain and protect the batteries attached to the power plant Charging the battery at the correct rate reduces battery heating increases the charge returned to the battery and prevents excess hydrogen generation or in the case of VRLA batteries possible thermal runaway Battery Maximum Recharge Current is set to the appropriate rate which is usually based on the size of the battery plant in Ampere hours A typical recharge current setting is battery capacity abbreviated
16. place when the system is operational or energized 3 4 Battery Connections 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 c Any jewelry rings or watches be removed while working on this equipment d Handles of all wrenches screwdrivers cutters and pliers are insulated Planning the Battery Installation The battery cable s should be sized sufficiently large to limit the voltage drop from the MX28B DC power plant to the battery during charging per system design requirements The cable s must also carry the full load current during battery operation f assistance is required to determine the necessary cables for the application contact your sales representative or APC An external fuse or circuit breaker various options are available from APC is recommended in the negative line located at the battery end to protect the cables from the battery to the MX28B DC power plant The power plant can monitor auxiliary contacts from this breaker MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 11 Connecting the Battery Cables WARNING Make certain that the battery polarity is correct when making connections to the Model MX28B DC power plant Incorrect connection could cause severe equi
17. to the rectifiers and the loads are disconnected from the system When the battery voltage reaches the threshold set by the LVD 7 Trip Voltage setting during discharge the DC power system will activate the LVD contactor to disconnect the battery or load from the system The LVD will remain open until AC power is restored to the system and the bus voltage reaches the level defined by the LVD 1 Reset Voltage variable 5 6 Controls and Indicators CAUTION The controller and the Web SNMP card have lithium batteries These batteries are not field serviceable e Danger of explosion if battery is replaced by an incorrect type e Dispose of used batteries according to the manufacturer s instructions Front Panel User Interface The MX28B control unit provides a user interface designed with a hierarchical menu that can be viewed on the 32 character 2 X 16 display by navigating with the lt left right up and 4 down arrow keys located on the front panel The selected item on the display is identified by the cursor cycling beneath its characters The M modify key and the arrow keys are used to set parameters and text to customize the system operation for a specific application Items that can be modified have m in the upper MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 35 right corner of the display If a security level higher than the one presently set is required to modi
18. 0 studs on 74 centers Ys studs on 1 centers 10 studs on 5 8 centers 10 studs on 74 centers Ys studs on 1 centers Figure 3 6 3 Plug in Circuit Breaker Kits MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 16 DC Bolt in Circuit Breakers Bolt in Breakers in a variety of sizes up to 700 Amps are available Triple pole breakers are available in sizes ranging from 400 700 Amps Double pole breakers are available in sizes ranging from 250 400 Amps Single pole breakers are available in sizes ranging from 100 225 Amps Small breakers half the size of a single pole breaker are available in sizes ranging from 1 100 Amps Two different panels are available for breaker mounting AAB 0647 has cutout holes for 4 triple pole breakers Each hole will accept one triple pole breaker 1 double and one single pole breaker or 3 single pole breakers AAB 0648 has cutout holes for 6 double pole breakers Each hole will accept one double pole breaker or 2 single pole breakers Each double breaker hole will accommodate 4 small breakers ranging in size from 1 to 100 Amps See Figure 3 6 4 for details Figure 3 6 4 Bolt in Circuit Breakers MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page 17 Telecom Fuses Telecom fuses in sizes ranging from 70 600 Amps are available A panel in each rectifier bay will accommodate 4 fuse holders Typical fuse numbering is Bay 1 Fuse 1 4 Bay 2 Fuse 5 8 Bay 3 Fuse 9 12 and Bay 4
19. 1 external contact closure or opening at the Input SYSTEM IN RLY RLY MAP Relay 1 connection changes state Input Relay 4 The Output Relay that is energized when an Security Level 1 external contact closure or opening at the Input SYSTEM IN RLY RLY MAP Relay 4 connection changes state Input Relay 1 Alias An alternate name alias can be assigned to Input In Rly 1 m Security Level 1 Relay 1 if desired Input Relay 1 SYSTEM IN RLY ALIAS Input Relay 4 Alias An alternate name alias can be assigned to Input Security Level 1 Relay 1 if desired In Rly 4 m SYSTEM IN RLY ALIAS Input Relay 4 Lamp Test Setting Lamp Test to ON will turn on the Lamp Test Security Level 1 MAJOR MINOR NORMAL MAJ and OFF SYSTEM DIAG MIN LEDs on the control unit front panel MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 40 PARAMETER NAME MENU LOCATION LVD 1 or 2 Option Security Level 1 MODULES LVD SET ALM LVD 1 or 2 Reset Security Level 1 MODULES LVD PARAM LVD 1 or 2 Trip Security Level 1 MODULES LVD PARAM LVD Alarm security Level 1 MODULES LVD SET ALM Model Programming Security Level 2 SYSTEM SETUP OEM R Gain security Level 2 OEM OEM R Offset Security Level 2 OEM OEM S Gain Security Level 2 OEM OEM S Offset Security Level 2 OEM Output Relay 1 Alarm Security Level 1 SYSTEM OUT RLY RLY MAP Output Relay 6 Alarm Security
20. 2400 MX28B1200 4800 48 VDC User s Manual Page 39 PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS FUSE 1 Blown The Output Relay that is energized when FUSE FUSE 1 Alm m Security Level 1 Fuse 1 is blown Major MODULES FUSE SET ALM FUSE 8 Blown The Output Relay that is energized when FUSE PUSE LO AW mF Security Level 1 Fuse 8 is blown Major MODULES FUSE SET ALM Hardware Battery Current The output relay energized if there is a hardware Batt C Almm Alarm failure in the battery current monitoring function Minor Security Level 2 SYSTEM SET ALM Hardware Battery Temperature The output relay energized if there is a hardware Hw Batt T Almm Alarm failure in the battery temperature monitoring Minor Security Level 2 function SYSTEM SET ALM Hardware LVD Alarm The output relay energized if there is a conflict Security Level 2 between the commanded and sensed positions of SYSTEM SET ALM the LVD contactor Generally the contactor is open when it should be closed Hardware System Temperature The output relay energized if there is a hardware Alarm failure in the system temperature monitoring Security Level 2 function SYSTEM SET ALM Hardware System Voltage The output relay energized if there is a hardware V Alm m Alarm failure in the system voltage monitoring function Minor Security Level 2 SYSTEM SET ALM Input Relay 1 The Output Relay that is energized when an Security Level
21. 6 1 Description Remote monitoring and control of the DC power system is accomplished through the use of the optional APC Network Management card This card is a separate module mounted into the top panel of the system controller module Complete documentation for the use of the management card accompanies the DC power system in the form of a small Quick Start Guide and a CD The CD contains electronic copies of Users Manuals along with the necessary software utilities to support the management function 6 2 Physical Connections The management card has a RJ 45 connector to support a TCP IP protocol over a 10BaseT Ethernet Local Area Network LAN The 9 pin D shell connector uses the special RS 232 cable APC part number 940 0024C to allow local access through a Terminal Emulation program like HyperTerminal or Procomm M 6 3 Command and Monitoring Protocol Refer to the Users Guides and associated documentation provided on the management card CD for the details on installation and use of the various communication protocols and command settings 7 Preventive Maintenance Preventive Maintenance is typically performed on a quarterly basis 7 1 Eguipment 1 4 Digit Voltmeter 2 Clamp on Ampere meter 3 Standard Insulated tools 7 2 Inspection Environmental Inspection Ensure the DC system environment is suitable for operation Ensure that there is sufficient clearance around the system for service Ensure that there i
22. B housing should mounted such that there is free airflow to the front and top of the unit Refer to Section 8 5 for environmental characteristics Free airflow should be ensured so that the power system can provide full power without de rating 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 MX28B DC power plant requires the supply of 208 220 240 277 VAC single phase 50 60 Hz power through individual external 20 amp circuit breakers to the AC input terminal block connections for each rectifier module in the system Two rectifier modules are required to accommodate the full AC input voltage range The 1MRF28H54BV rectifier is designed for the standard 208 220 240 VAC input service while the 1MRF28H54BV50 is used for the 277 VAC MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 9 input The AC wiring from the AC input terminal block connections to the hot pluggable AC input connector for each rectifier is factory installed The AC input enclosure located at the top rear of the MX28B rectifier bay is provided with nine Va inch pilot holes in the top plate Remove the ac input enclosure from the box frame in order to punch or drill the appropriate number of conduit openings for the conduit size s desired Do not le
23. E EEEE EEE AEE 54 6 2 PHYSICAE ellene KEE 54 MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page il 6 3 COMMAND AND MONITORING PROTOCOL Ge ee ee ee ee ee 54 7 PREVENTIVE MAINTENANCE sees ee ske ee ee ske ske eke sk eek ee eke Ek eek Re ERGER ee eke eke ee eb Rek ee eke Ek eek Re Re EE 55 EM Si Ed EE EE EE EE EE RE OR RE CG 55 42 MM BECHOD Mo ni 55 ENVITONIMEN TA Te e EE 55 System Visual and Safety INSpection iii 55 Battery Visual and Safety Inspection ie Ee Ee ER ER ER EE ER ee Ee ee ee ee Ee ek Ee ee LL ee ana 56 e Get NEE 96 System Vollade Test sis SS RR INF IH FD FD eer 56 Eege eer EE 56 Iseculer cunent Share Test EE 57 VOCON Wes Ene eee E E ene ere 57 RECAI TESK SE EE Ee 57 System Temperature ToS lepse EE EE Gy o a Oe y GY RD RO 5 naa Cunen TOST siii OL eege 57 Ballen EE TOS eese E EEE EER EE RE E TE 58 BV E EE 58 Battery Preventive Maintenance Procedure ss see see see see eek ee eek Gee ee eek ee LLY eek ee 58 gt FINAEINSPEOTION MEE EE Eg 99 E a ee ei ag el LEE 60 Gele PCN a 60 TMESISZOFIOTBV ISOCITIOES ioni ribalta 60 TMRE26HO4BVOO FReCIITIGOES ugeet io 60 8 2 _ DC OUTPUT WITH EITHER 1MRF28H54BV RECTIFIERS AND 1MRF28H54BV50 RECTIFIER E 61 0 0 CONTROLS ANDIINDIGATORS susse We SU See OE OGE vi b SEE E GN De Ee ge See GE Doe SE eras 61 EE EE 61 Powenonel Control Uni ES NO Y UF OF NF buds 62 G4 E due ler 63 3 0 ENVIRONMENTAL
24. EE EE ER ER ER ER EE ER Ee Re ee Ee ee Ee ek Gee Ee nana 19 Bolt in Circuit Breaker InstallatiON ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 20 Telecom Fuse InstallallOf ilaele 21 GMT US InstallallORE EE SE EE EE EE I GE DE GE DE GE EE GE GEE GE EE GER DEEG 21 3 8 KOAD CONNEC HONG EE 22 Cable Size Considerations EE 22 Circuit Breaker Connections 1 to 50 Ampsl ee EE EE ER RR ER ER EER Ee Re YNN Ee ee Se ee See Ee ee 22 Circuit Breaker Connections 60 100 Amps EE EE EE iii 22 etd CORNECHONS 1 100 AMPS EE AE GU Uu IU RA CG CY CN GY y EY GO GAN 22 CEN USOC ONC CHO Sorat o O YN YR RW Y 23 3 9 MONITORING AND RELAY OUTPUT CONNECTIONS ee ee ee ee i 23 Front Panel DB9 Connection illa 23 Sma Cabe DB CONNECHOnN EE EE EE EE EE GE AUAN lara Ee Ge Ee OL 23 RJ45 Ethernet Connector EE ee ee ee ee ee 24 relay OUTPUT lee e CN 24 MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page ii 3 10 EXTERNAL ALARM INPUT CONNECTIONS cccccceccecccccccccctecceaueccecaueatesueccecanesuesuecseeanesnesees 25 os JRECTIFIER MODULE INSTALLATION ui ESEG SES GED GEE ER O 26 4 COMMISSIONING AND PREVENTIVE MAINTENANCE ee ee eke ee ee Hm 27 4 1 PRE COMMISSIONING INSPECTION 2 FIOM EEN 2 PIC CIC Al stal ORE EE EG AD RD EE AE nn 2 Battery Visual and Safety Inspection ER ER ER Ee Ee Ee ee eek eek Ee ee nna na 2 4 2 ei Elle He 28 MUI SEUD EE 28 AGF OWOF UD EE 28 DE Po
25. IEEE Ee ee ee ee ean Gee Fd O 14 FIGURE 3 6 1 DC DISTRIBUTION FRONT COVER OPENED 15 FIGURE 5 6 2 PLUG IN CIRCUIT BREAKERS EE 16 FIGURE 3 6 3 PLUG IN CIRCUIT BREAKER KITS AAA 16 FIGURE 5 6 BO TANGIRELUIT EE 17 FIGURE 376 5 TELECON FUSES eie deel 18 FIGURE 3 7 1 INSTALLATION OF CIRCUIT BREAKERS 2 see see ee enne 19 FIGURE 7 2 CIRCUIT BREAKER ALARM Eege Sid oe ato 20 FIGURE 3 7 3 GMT FUSE TEMPERATURE DE RATING CHART ll ll luccio 21 FIGURE 3 8 1 LOAD CONNECTIONS FOR SNAP IN BREAKERS AAA 23 FIGURE 3 8 2 RE TURN CONNEC THON E 23 FIGURE 3 9 LANTERFAGE BORD E 24 FIGURES 9 2 OUTPUT RELAY CONNECTIONS e 25 FIGURE 3 10 1 EXTERNAL ALARM INPUT DEFINITION esse eke ees ee se se ss ss ses de ee ee ee se eke ee ee 25 FIGURE 3 10 2 EXTERNAL ALARM INPUT CONNECTIONS AAA 25 FIGURE 0 LNMENU TOP CINE elena 36 MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page v 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 WARNING The DC power plant is supplied from a nominal 220VAC 50 60 Hz source Keep the AC input enclosure cover in place when the system
26. Installation 3 5 DC System Grounding The Positive Battery connection return bus for the power plant must be connected to the Master Station Ground The return bus provides 3 8 holes on 1 inch or 1 3 4 inch centers for connection of a two hole lugged cable to the Central Office Ground Details for this connection should be provided in the site electrical grounding plans A connection to tie the frames together is also available At the top of both sides of the box frame is a pair of studs for connecting a grounding cable This 6 AWG cable is provided with each expansion frame MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 13 ih 4 Tn HS BEEN EHUENNE A LO ranun te Ni Y gt umm m e a e PEN aa fe Figure 3 5 1 DC System Grounding Figure 3 5 2 Box Frame Ground 3 6 DC Power Output Over Current Protection There are several different options for DC output power distribution Distribution provides a convenient method of connecting the load cables as well as over current protection DC Plug in Circuit Breakers A standard 48 position plug in circuit breaker tier provides 48V distribution Various circuit breaker sizes from 1 to 100 amps are available with 60 100 amp breakers requiring two positions and a circuit breaker adapter kit Each rectifier bay has two 24 position breaker tiers Each breaker tier is connected at its center to the 48V DC bus and each side of the tier has a total current capac
27. LF 4 mi Em E EE EE T Jt JT GEE SHELF CNTLR PCB AC INPUT RECTIFIER EAA 0062 MEN 5 O Yn SHELF 5 eii RECTIFIER EEE HI de EE NET INN N 6 Je SHELF 6 ENTER AC INPUT FEH SHELF an E ee SHUNT i e LVD CNIL PCB E vp BLK EAA 0078 2 BATTERY BATTERY BATTERY BATTERY LVD ASSEMBLY CURRENT Figure 2 2 2 MX28B Block Diagram MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 4 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 CAUTION Appropriate lifting techniques and safety equipment should be used to remove equipment from packing PLEASE RECYCLE The shipping materials can be recycled Please save them for later use or dispose accordingly 3 2 Mechanical Installation Room Location NOTE The APC Model MX28B DC power plant is to be installed in a room vault or similar enclosure that is accessible only to qualified persons in accordance with the NEC or the authority having jurisdiction Prior to installation drawings floor loading requirements ex
28. M DIAG front panel Test Relay Enable This parameter must be set to Enable to permit Test Relay En mt Security Level 1 the eight output relays to be manually tested Disable SYSTEM DIAG otherwise the state of the relays will be per system conditions MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 44 PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Time Internal system clock time 24 hour format Used Time m Security Level 1 as a date stamp in the event log eet TOE SYSTEM DATE MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 45 Control Unit Menu Structure The complete menu structure shown in the order in which it is accessed from the control unit display is presented in outline form below Each indentation to the right represents a menu level below the indicated title STATUS ALARMS sys Voltage posi were CSS EE E MX28B 1200 US ALARMS SYSTEM Alarm Item 1 Alarm Item 3 Alarm Item 14 MX28B 1200 Svs MS SYSTEM MODULE SET ALM SETUP DA Sys HV Thr oys LV Alm Rect lofN Alm Sys ILE Thr Sys HT Alm Sys LT Alm Hw Sys V Alm MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 46 Hw Batt C Alm Top Level Second Level Third Level Fourth Level Hw Sys T Alm UE DS LM SETUP DATE PIN 1 leng leng OT me ees i ES DT eee S E due S DT ese ES Oes fee ev S ew version OO e Display Type SYS
29. The PSCU can trigger output relays in the event of a rectifier alarm Refer to Section 5 6 for PSCU control functions MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 32 5 3 System Management System Output Capacity The power plant has two basic configurations The MX28B 1200 2400 supplies a maximum of 2400 amps or 2350 amps with N 1 redundancy The housing for this configuration provides two rectifier bays with integrated DC output distribution a control unit and expansion bays for added DC output distribution The MX28B 1200 4800 supplies a maximum of 4800 amps or 4750 amps with N 1 redundancy The housing for this configuration provides four rectifier bays with integrated DC output distribution a control unit and expansion bays for added DC output distribution The difference between the MX28B 1200 2400 Main Bay and the MX28B 1200 4800 Main Bay is the size and configuration of the power bus and battery shunt All other parts are the same for both configurations System Voltage Control The PSCU monitors and adjusts the system voltage It uses a voltage trim input to the rectifier to precisely control the DC output voltage In the event of PSCU removal or failure the shelf rectifier controller card will control the voltage at a programmed default level In the event of shelf rectifier controller card failure the individual rectifiers will default to the analog voltage level preset with the front panel float adjustment pots
30. USE LO FUSE 11 FUSE 12 FUSE 13 FUSE 14 PUSH Lao FUSE 16 O TL MOD LVD MT LVD SET ALM PARAM LVD do OBE OEOD LVD 1 Open Alm OD o G LO Al DS LVD 2 Open Alm MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 50 Top Level Second Level Third Level Fourth Level MORB ST VI LM PARAM GYD Trip ES DATI PIN OEM SET ALM PARAM C Bact Disc The gt lt men ie men le meu Oe wa Oe wa Oe ae NEE mera o SS _ Batt LT Alm BAT S LM PARAM COMP Batt FF lLOaL Batt Max Rech EE ps ie lesen AM COMP Comp Method NEE E O E tme des MX28B 1200 ES BATT PIN OEM PIN MX2aB 1200 EE PIN OEM OEM R Offset MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 51 Front Panel LED Indicators EETL MIN Red On when Minor Relay is energized MAJ Red On when Major Relay is de energized This will produce a major relay output even when all power is lost 5 7 Alarm Outputs Output Relays There are eight alarm output relays designated Relay 1 through Relay 6 Minor and Major respectively Various system parameters may be programmed to activate any of these alarm relays when set thresholds are exceeded or specific conditions occur The first six relays can also be assigned a priority and routed or mapped to other output alarm relays Available assignments are Ignore Major Minor and Relay 1 Relay 6 Screens for making
31. X28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 25 3 11 Rectifier Module Installation WARNING Rectifier DC output circuits would be damaged if battery were installed incorrectly Before rectifier installation ensure proper battery polarity and that the battery is isolated from the rest of the system The rectifier modules are shipped in separate containers Follow the procedure below to install a rectifier module 1 Remove the rectifier from its shipping container 2 Remove any rectifier retaining screws from the shelf position where the rectifier is to be installed 3 Slide the rectifier module into the shelf between the guides until it is fully seated 4 Fasten the rectifier in place with the rectifier retaining screw included in literature kit with product manual Since all adjustments are made from the system control unit no rectifier adjustments are necessary NOTE All FLOAT BOOST EQUALISE switches one is located on the front of each rectifier in the system must be set to FLOAT to allow the MX28B to control the output voltage properly CAUTION Rectifier fan inlet filters are available for dusty or hostile environments Failure to periodically check and clean filters can lead to rectifier shutdown due to over temperature and produce power plant failure MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 26 4 Commissioning and Preventive Maintenance 4 1 Pre Commission
32. amps 3 Verify that the displayed battery current is within 5 amps Adjust OEM S Offset if required 4 Determine the total battery capacity at the site Cells connected in series make up a string and the capacity is determined by the capacity of a single cell Add amp hour capacity for all strings connected in parallel Enter the total battery capacity in the appropriate box on the Site Form 9 Determine the Max Batt Recharge rate Divide Total battery capacity by 20 hours and enter it in the appropriate box on the Site Form 6 Verify that the Max Batt Recharge rate is set to the calculated value 7 Remove AC power to the rectifiers purposely causing the battery discharge alarm to come on 8 Verify that the System Current is 0 5 amps 9 Verify that the battery current is within 5 of the system current recorded previously 10 Verify that the Battery Discharge Alarm is on 11 Restore AC power to the rectifiers MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 57 Battery Temperature Test If the battery teperature probe is used in this system verify that the battery temperature is correct LVD Test 1 OO EP ai 21 8 9 Verify that the LVD Open Alarm has been removed Verify that the Battery Float voltage is set to negative 54 00 Volts via the control panel and verify the temperature compensation setting is at its default setting disabled Enable the LVD s that are installed Note In sin
33. as C divided by number of charging hours As an example a C 10 rate will basically return the battery to full charge in 10 hours A C 8 rate is probably the highest current which should be considered for charging under normal circumstances MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 34 Battery Temperature Compensation The Battery Float Voltage is set to the value recommended by the battery manufacturer in order to maintain correct battery charge at 25 C As temperature rises electrochemical activity in a battery increases Similarly as temperature falls electrochemical activity in a battery decreases As temperature rises charging voltage should be reduced to prevent overcharge and increased as temperature falls to prevent undercharge The DC power system uses Battery Temperature compensation to change output voltage to compensate for temperature changes This temperature compensation function is programmed into the PSCU using the compensation parameters settings Default settings can be changed to values recommended by the particular battery manufacturer Battery Load Low Voltage Disconnect In order to prevent damage to the battery due to deep discharge the DC power system has hardware and software support for a battery or load Low Voltage Disconnect LVD A battery LVD has the loads permanently attached to the rectifiers and the battery is disconnected from the system A load LVD has the battery permanently attached
34. ature Sys LE The m Threshold measured inside the controller An alarm will be 0 0 C Security Level 1 reported if temperature is lower than the SYSTEM SET ALM temperature entered Security Level 1 is below the System Low Voltage threshold Minor SYSTEM SET ALM System Low Voltage Threshold System Voltage is bus voltage measured by the Sys LV Thr m Security Level 1 controller An alarm will be reported if voltage is BO d V SYSTEM SET ALM lower than the voltage entered ots LN Status Only unit En e STATUS ats ow Status Only MX28B DC power plant 48V and return buses zB qur V STATUS Test Major Relay Setting this parameter to ON de energizes the Test Maj Rly m Security Level 1 Major Relay and turns on the MAJ LED on the OFF SYSTEM DIAG control unit front panel In normal operation Major Relay is energized so that when a loss of 48 VDC power occurs the relay will change state Test Minor Relay Setting this parameter to ON energizes the Minor Test Min Rly m security Level 1 Relay and turns on the MIN LED on the control OFF SYSTEM DIAG unit front panel Test Relay 1 Setting this parameter to ON energizes Relay 1 Test Relay 1 mr security Level 1 and turns on the ALM1 LED on the control unit OFF SYSTEM DIAG front panel Test Relay 6 Setting this parameter to ON energizes Relay 6 Test Relay 6 mt Security Level 1 and turns on the ALM6 LED on the control unit OFF SYSTE
35. ave the ac input enclosure in place when punching or drilling holes in order to prevent metal pieces from falling into the power system AC wiring passing through the conduit will be routed through the access opening in the ac input enclosure into the vertical wiring channel where safety ground bar and rectifier input terminal blocks are located The terminal block s is labeled as Rectifier 1 through Rectifier 4 with each position having inputs designated L1 and L2 N for connection of the two ac wires Figure 3 3 1 Each terminal block represents connections for one shelf with positions 1 through 4 corresponding to the rectifier shelf positions numbered from left to right as viewed from the front n F ba a Figure 3 3 1 AC Input Wiring The suggested wire size is 10 AWG rated at 90 C or higher however the ambient temperature and number of wires in a conduit must also be considered in accordance with NEC requirements It is suggested that feeds for four rectifiers 8 wires and one safety ground wire be run in a one inch conduit however be sure to follow any local electrical wiring codes MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 10 If the AC input power is provided from a three phase distribution panel the circuit breaker positions should be selected such that the load is balanced as much as possible WARNING The MX28B DC power plant is supplied from a high voltage source Keep the AC input enclosure in
36. ctifier modules Note that some specification items are provided on a per rectifier basis and must be combined or totaled for a give system configuration 8 1 AC Input 1MRF28H54BV Rectifiers Nominal Input Voltage 208 230 VAC Input Voltage Range 176 264 VAC AC Frequency Range 45 65 Hz Apparent Power Factor 99 Typical 98 Minimum Maximum Input Current per Rectifier 13 9 Amps 230V AC 1MRF28H54BV50 Rectifiers Nominal Input Voltage 2 7 VAC Input Voltage Range 176 293 VAC AC Frequency Range 45 65 Hz Apparent Power Factor 99 Typical 98 Minimum Maximum Input Current per Rectifier 11 0 Amps 277V AC 8 2 DC Output with either 1MRF28H54BV Rectifiers and 1MRF28H54BV50 Rectifiers Nominal Output Voltage factory set 54 5 VDC Operating Voltage Range 44 58 VDC Rated Output Power per Rectifier 2800 W 45 C Efficiency 91 Typical 8 3 Controls and Indicators Rectifiers Input Healthy LED AC power present Output Healthy LED DC output voltage within operating range 39 5 to 59 5 VDC Overtemp LED On when one of three internal sensors is above 130 C Power Conversion is inhibited Fan fail LED On when Fan is running too slow Standby LED On when the unit is in the standby mode No output power is produced Rectifier is still active V Test Point Rectifier Voltage can be measured with a voltmeter between COM and V COM Test Point Negative reference for both V an
37. d An alternate name alias can be assigned to Output Relay 6 if desired MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual DISPLAY SCREENS DEFAULT SETTINGS LVD Option WE Enable LVD Reset m USD N Ly ED m AO V LVD Open Alm m Minor Model m MX28B 1200 OEM R Gain m T 000 wv OEM R Offset mt DEER SE OEM S Gain m lei OO JA OEM S Offset m Ou a Out Ily l1 Adm mc Ignore Eer 6 APE EE LIODOrFe Page 41 PARAMETER NAME MENU LOCATION Output Relay 1 Delay security Level 1 SYSTEM OUT RLY RLY MAP Output Relay 6 Delay Security Level 1 SYSTEM OUT RLY RLY MAP Output Relay Major Alias Security Level 1 SYSTEM OUT RLY ALIAS Output Relay Minor Alias Security Level 1 SYSTEM OUT RLY ALIAS PIN 1 change Security Level 2 SYSTEM SETUP PIN 2 Change security Level 2 SYSTEM SETUP PIN Entry Security Level 0 PIN Rectifier Communications Fail Timeout Security Level 1 MODULES RECT PARAM Rectifier Configuration Alarm security Level 1 SYSTEM SET ALM Rectifier Current Limit Alarm Security Level 1 MODULES RECT SET ALM Rectifier Current Limit Alarm Status Status Only MODULES RECT INFO Rectifier Current Output Status Status Only MODULES RECT INFO DESCRIPTION DISPLAY SCREENS DEFAULT SETTINGS Delay between sensing of the alarm condition and Out Rly 1 Dly m activation of Output Relay 1 An alarm co
38. d l Test Point Rectifier Current can be measured with a voltmeter between COM and l MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 61 Float Boost Equalize Used to Control voltage on systems without a PSCU Switch Float Trim Pot The float pot is used to adjust the default float voltage 54 5 VDC Boost Equalize Trim The boost equalize pot is used to adjust the default boost equalize Pot voltage 57 5 VDC Power Shelf Control Unit MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 62 8 4 Mechanical 54 gh x 26 wide x 26 deep Weight Housing 400 600 Ibs 181 272 Kg Rectifier each 11 Ibs 5Kg 8 5 Environmental Ambient Temperature Operating 45 C to 55 C 65 C with reduced power output Storage 45 C to 85 C Humidity Operating 0 89 RH non condensing Storage 0 95 RH non condensing Altitude Operating 3000 m 9840 ft Storage 10000 m 39370 ft 8 6 Compliance Safety UL 1950 MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 63 9 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 e 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 Corporate Headquarters Connec
39. e formula Voltage X 10amps volt 3 Rectifier current displayed under Rectifier Info should agree with the recorded current MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 56 Rectifier Current Share Test Verify that the highest rectifier current and the lowest current are within 5 amps System Current Test Verify the System current equal to the total of the rectifier currents System current should equal the total current of the loads as well as any battery current Rectifier Alarm Test 4 S 6 f 1 Verify that all of the rectifiers report RFA Alarm is off 2 3 Remove 1 rectifier and verify that you get a Minor alarm for Rect 1 of n failure on the Verify that the battery voltage reading on the voltmeter is negative 54 00 0 02Volts controller and the customer remote alarm panel Remove the second rectifier and verify that you get a Major alarm for Rect 2 of n failure on the controller and the customer remote alarm panel 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 Verify that you get the fan fail alarm on controller and the customer remote alarm panel Remove the fan fail device System Temperature Test Verify that the system temperature is correct Battery Current Test 1 Measure the battery current with a clamp on meter 2 Verify that the battery current is below 5
40. ection 1 Check that the battery temperature probe is firmly attached to the battery 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 Cracks Case leaks Post seal leaks Pressure relief valve leaks VRLA only Case swelling VRLA only f Terminal corrosion and connector corrosion 6 Check the torque of all battery inter cell connector in accordance with specifications Re torque if necessary annual only 7 Measure and record ambient temperature EE 7 3 Test System Voltage Test Verify with a voltmeter directly attached to the DC bus that the system voltage is correct If the voltage is off by more than 0 1V recalibrate the controller with the OEM R Offset setting system voltage should also agree with the battery float voltage set up in the battery parameters section The system may be off because of battery temperature compensation or battery recharging Rectifier Current Test 1 Insert voltmeter probe between I and common jack on front of each rectifier 2 Record current for each rectifier using th
41. erature Compensation Method One of three parameters that control the DC Comp Method m Security Level 1 output voltage Activate ON or de activate OFF OFF BATT COMP battery temperature compensation Compensation Temperature Temperature compensation coefficient between Comp TC Coefficient low knee and high knee in mV cell C Security Level 1 Compensation equals zero at 25 C BATT COMP Control Unit Revision Hardware revision level of the control unit This Cntii Rev Status Only parameter cannot be changed 000002 SYSTEM SETUP Date Internal system calendar date Used as a date Date Security Level 1 stamp in the event log DEC TG Oo o SYSTEM DATE Status Only parameter cannot be changed 000255 SYSTEM SETUP Fahrenheit Scale Enables selection of Fahrenheit or Celsius Fahrenheit Security Level 1 temperature scale Fahrenheit OFF displays SYSTEM SETUP readings in C Firmware Version Version number of the control unit firmware FW Version Status Only NOTE Actual firmware version number 000189 SYSTEM SETUP displayed is the current version as of the date of manufacture This parameter cannot be changed FUSE 1 Alias An alternate name alias that can be assigned to Security Level 1 a FUSE Fuse 1 if desired MODULES FUSE ALIAS FUSE 8 Alias An alternate name alias that can be assigned to FUSE 16 m security Level 1 a FUSE Fuse 8 if desired MOV MODULES FUSE ALIAS MX28B1200
42. es DC distribution section with the front cover opened A NL Vi 4 WT Ted d M t LR D i Sin 207 1 TE L W H a V a LI a GETEKEN 1323213108 J ELD LLL ET CI dre ees a o amp H A il unm T d am e H y k ne n i i GM N E m EN Fis 1 vam Ew KC Steet EC 8 RARE E E n CES efr bar ra JEE EIERE Tina in Figure 3 6 1 DC Distribution Front Cover Opened Available plug in circuit breakers are shown in Figure 3 6 2 These are only breakers and do not include any hardware Plug in circuit breakers rated at 60A or more require two mounting positions and require a circuit breaker adapter which is included in the circuit breaker kit Adaptors are available with studs for 10 32 nuts on 5 8 centers 10 32 nuts on 74 centers or 4 20 nuts on 1 centers The circuit breaker kit includes all necessary mounting hardware Available plug in circuit breakers are shown in Figure 3 6 2 BREAKER BREAKER Sien PART NUMBER p RATING PART NUMBER 1A FFA 0014 ann 40A A FFA Fran MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 15 FFA 0018 a 100 A 530 9094 Figure 3 6 2 Plug in Circuit Breakers BreakerRating Part Number Adaptor Size FFA 0021 1 10 studs on 5 8 centers 10 studs on 74 centers 74 studs on 1 centers 10 studs on 5 8 centers 10 studs on 74 centers 74 studs on 1 centers 10 studs on 5 8 centers 1
43. fy the parameter s is displayed instead of mt Status alarms and information screens have in the upper right corner of the display or in the case of rectifier information screens and cannot be modified When AC power is initially applied there is a 60 second period during which no alarms are reported Pressing the M key on the front panel will change the m to M indicating that the parameter can now be changed using the arrow keys Some parameters can be changed to other predefined selections by pressing the up or down arrow keys to display an alternative selection These parameters can be recognized after the M key is pressed by the cursor cycling beneath the characters of the selection For other parameters such as text and most numeric values after the M key is pressed the cursor will be displayed under an individual character The right or left arrow key is used to position the cursor below the character to be changed and the up or down arrow key is used to spin the digit or letter to the desired value When the desired changes have been made to an individual parameter screen the M key is pressed again the M changes back to m and the new entry is stored in memory If the user plans to make any changes to system parameters the first item that should be verified or entered is the appropriate password for the security level required for the parameters to be modified Security level 2 enter 2222 on the
44. gle bay systems only LVD1 is used In multi bay systems LVD1 and LVD2 are used in parallel Ensure that the LVD parameters are set to proper value Install rectifiers and restore AC power Set the LVD Trip to 56 00 Volts The LVD should have dropped out opened Verify it by monitoring the voltage at the battery connection Verify that the L VD Open Alarm is registered on the controller and at the customer remote alarm panel Reset the LVD Trip to negative 42Volts 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 Atthe power bay bus b Atthe battery c Reset voltage if necessary Measure the float current on each battery cable If it is fluctuating measure maximum and minimum Measure the AC ripple voltage at the battery Using an Alber Cellcorder measure the float voltage of each cell or monoblock Record the battery memory location allocated on the Cellcorder Using an Alber Cellcorder perform a load test on each cell or monoblock and measure the internal cell resistance and inter cell resistance of each cell or monoblock Measure and record the specific gravity of each cell using a
45. h rectifier should be switched on and off to ensure that you have power at every rectifier and that the breaker disconnects the rectifier Verify that all of the circuit breaker positions are labeled to the corresponding rectifier correctly Insert all rectifiers Turn all rectifier circuit breakers on The main screen should appear on the control unit display see Figure 5 6 1 The display on the control unit is a 2 lines by 16 characters display The cursor cycles below the characters of the active selection on the display Information shown in the second line of Figure 5 6 1 that extends beyond 16 characters to the right of the S in ALARMS can viewed on the control unit display by using the scrolling controls refer to Section 5 6 for operation of the control unit MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 28 DC Power Up T Verify with a voltmeter that the dc voltage is within 0 1 Vdc of the System Voltage If the voltage is off adjust the R offset setting under the OEM menu If the R Offset setting is more than 1 00 Volt dc contact APC for a replacement controller module 2 Adjust battery float voltage to negative 49 Volts 3 Verify System Low Voltage Alarm 4 Adjust battery float voltage to negative 57 Volts 9 Verify System High Voltage Alarm 6 Restore the battery float voltage to negative 54 00 Volts or desired voltage Rectifier Test 1 To verify that all rectifiers are reporti
46. ier alarm group n of N that occurs when a n of N MODULES RECT SET ALM rectifier fan has failed Rectifier Fan Fail Alarm Status The status will be ON if the rectifier fan has Rect 1 FF Status Only failed NOTE This information can be viewed OFF MODULES RECT INFO for each rectifier installed by using the horizontal arrow keys Rectifier Fault Alarm RFA The status will be on if the rectifier output has Rect 1 RFA Status failed NOTE This information can be viewed Status Only for each rectifier installed by using the MODULES RECT INFO horizontal arrow keys Rectifier RFA Alarm The output relay that is energized or special Rect RFA Alm m Security Level 1 rectifier alarm group n of N that occurs when a n of N MODULES RECT SET ALM rectifier output has failed Rectifier Standby Alarm The output relay that is energized or special Rect Stdby Almm security Level 1 rectifier alarm group n of N that occurs when the n of N MODULES RECT SET ALM control unit is holding a rectifier in the standby mode Rectifier Standby Alarm Status The status will be ON if the control unit is holding Rect 1 Stdby Status Only the rectifier in the standby mode NOTE This MODULES RECT INFO information can be viewed for each rectifier installed by using the horizontal arrow keys Store Configuration Setting this parameter to Enable will cause the Stone CLG m Security Level 1 current rectifier configuration to be
47. ing Inspection Environment 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 Consult with customer to disable installed customer alarms before servicing the unit This will allow the unit to be serviced without creating false alarms saa cali ME Electrical Installation Ensure that the DC wiring is properly installed sized terminated and identified Ensure that the AC wiring is properly installed sized terminated and identified Ensure that the battery is properly connected to the System Ensure that the DC output over current protection devices are adequate for the size of wiring installed 5 Ensure that the DC Positive is bonded to central office ground 48 volt system 6 Note the resistance of the ground bond 7 Note any currents flowing in the ground 8 9 1 DR EE Record ambient temperature Verify that the battery polarity is correct 0 If a battery disconnect device s is are present note the following for each device a DC Voltage Rating b DC Current Rating c Interrupting Current Rating Battery Visual and Safety Inspection 1 Check the mechanical integrity of the battery framing racking or cabinet 2 Check that the battery framing racking or cabinet is adequately secured to the floor 3 Check compliance with seismic zone requirements 4 Check the genera
48. inspection results in identification of a material or workmanship flaw s that could impair Product performance as defined by APC s electrical and physical specification in effect at the time of shipment and if this flaw s is not due to transportation damage or installation abuse contact APC or call the 24 hour emergency number 800 800 4APC to request assistance You will be provided either a an RMA number with instructions for return of the equipment or component s to the APC factory service center FOB destination freight pre paid for examination or b for non returnable systems and equipment notice to wait until an APC authorized service representative arrives at the site to inspect the equipment Repaired or advance replacement modules or circuit components will normally be available within 24 to 48 hours of receipt of equipment or RMA Warranty Obligations Repair or Replacement If during the warranty period the Product is found to be physically or electrically faulty due to defective materials or workmanship the defective Product s or component s will be repaired or replaced at the sole option of APC If the procedure outlined above for contacting APC immediately after identifying a material or workmanship flaw s that could impair Product performance has been properly followed such repair or replacement of Product s or component s shall include all charges for replacement materials or repair labor Costs incurred for replaceme
49. ire load can be run from a fuse or circuit breaker bay mounted next to the rectifier bays The MX28B 1200 2400 has a maximum of two rectifier bays The MX28B 1200 4800 can be expanded to four rectifier bays The power buses are connected together in each bay by splicing the buses together The MX28B1200 2400 is a 1200 Amp system expandable to 2400 Amps The MX28B 1200 4800 is a 1200 Amp system expandable to 4800 Amps Each MX28B 1200 2400 power bus is comprised of 2 laminations of 5 X 1 4 bus See Figure 3 2 2 for details Each MX28B 1200 4800 power bus is comprised of 3 laminations of 6 X 1 4 bus See Figure 3 2 3 for details The power bays are spliced together with splice plates provided with each expansion bay The size and thickness of the splice plates must match the power bus See Figure 3 2 4 for details MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 6 Figure 3 2 2 MX28B 1200 2400 has a maximum Figure 3 2 3 The MX28B1200 4800 can be capacity of 2400 Amps expanded to 4800 Amps Figure 3 2 4 Splice Plate Installation MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page Circuit Breaker LVD Ribbon Cable Connections Additional cables must be connected between cabinets to ensure that the circuit breaker alarms in the expansion bays are reported correctly The circuit breakers and LVDs are connected together through the use of a Circuit Breaker LVD Expansion Board The ribbon cables on the left hand side of the b
50. is operational or energized 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 a Any jewelry rings or watches be removed while working on this equipment b Handles of all wrenches screwdrivers cutters and pliers are insulated WARNING Ensure that all of the DC and external 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 Specific CAUTION and WARNING will be placed in manual where appropriate MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 1 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 All system settings are made from the system control unit that provides monitoring and control functions for each component of the system as well as alarm listings for system diagnosis and maintenance The APC Model MX28B is a modular stand alone 48V DC power plant It is configurable in such a manner that it will support most typical applications within the specified
51. ity of 300A Each breaker tier has a total current capacity of 600A Each rectifier bay has a total current capacity of 1200A It is therefore necessary to balance the load on the rectifier bay to avoid overloading any section of the output bus Also when planning the output installation take into consideration the configuration of the plant and the number of rectifiers installed Any combination of up to 48 single 1 50 Amp or up to 24 double 60 100 Amp breakers may be installed If all rectifier bays are installed with snap in breakers up to 192 single or 96 double breakers may be installed In the main bay a pair of ribbon cables routed directly to the controller backplane handles alarming In the expansion bays each 24 breaker tier is alarmed as a group of breakers A two pin connector on each tier connects to the Circuit Breaker expansion board in each bay Circuit breaker alarms can be monitored by attaching the other end of the alarm wire to the gray Wago connector on the Circuit Breaker LVD Expansion board Since the normally open contacts are monitored any tripped breaker will give an alarm Install the alarm wire in the Wago connector on the expansion board Jumper the pins behind the Wago connectors based on what bay the circuit breaker tiers are in Typical circuit breaker numbering is bay 1 Cir Bkr 1 48 Bay 2 Cir Bkr 49 50 Bay 3 Cir Bkr 51 52 and Bay 4 Cir Bkr 53 54 Figure 3 6 1 shows the power plants main bay with ribbon cabl
52. l appearance and cleanliness of the battery 5 Record the manufacturer model number and capacity of the battery string s on Site Form 6 Record the batch number date code and serial number of each cell or mono block and any other pertinent information that is available on the battery cells on the Site Form 7 Check that the cell or mono block numbering starts at the positive battery string terminal and is correct 8 Check that anti oxidation compound is properly applied 9 Visually inspect each cell for a Cracks Case leaks Post seal leaks Pressure relief valve leaks VRLA only Case swelling VRLA only Case swelling VRLA only mosso 10 Check the torque of all battery inter cell connector in accordance with the battery 4 2 manufacturer s specifications Commissioning Initial Set up SI Remove all rectifiers Ensure that the float equalise switch is on float Disconnect battery by removing a link in each string or opening the battery disconnects Check that battery voltage does not appear on the system bus Disconnect all loads AC Power Up 1 DI 9 WARNING The DC power plant is supplied from a nominal high voltage AC voltage source Keep the AC input enclosure cover in place when the system is operational or energized Verify that AC voltage is present for each rectifier at the back plane position Blue J2 of OP 9131 inside the rectifier compartment The AC input breaker for eac
53. meters that can be accessed in this category starting from the main menu screen do the following MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 36 1 Use the right or left arrow keys to position the cycling cursor below SYSTEM 2 Press the down arrow key once 3 Use the right arrow key to position the cycling cursor below IN RL Y 4 Press the down arrow key once the cursor will be cycling below RLY MAP 5 Press the down arrow key repeatedly if necessary until the desired parameter screen is displayed there are eight parameter screens in this category After making any desired changes return to the main menu press the up arrow key repeatedly If a parameter requires a level 1 or level 2 security access to permit changes to it the security level will be found in braces i e Security Level 2 in the PARAMETER column of the table Parameter Locations Descriptions and Default Values PARAMETER NAME MENU LOCATION Address 1 Security Level 1 SYSTEM SETUP Address 2 Security Level 1 SYSTEM SETUP Address 3 Security Level 1 SYSTEM SETUP Alarms ltem 1 Status Only ALARMS Alarms Item 16 ALARMS Battery Current Status Only STATUS Battery Discharge Alarm Security Level 1 BATT SET ALM Battery Discharge Threshold Security Level 1 BATT SET ALM Battery Float Voltage Security Level 1 BATT PARAM MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual
54. n individual hydrometer or Cellcorder attachment hydrometer VLA only Ensure that the electrolyte level is adequate Add approved water where necessary VLA only Measure and record the temperature of the electrolyte of each cell VLA only MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 58 9 Ensure that all protective covers are replaced and that the battery is electrically non hazardous to personnel that could be working in the vicinity Detail any discrepancies 10 Download the Cellcorder to a PC and create a data file for each battery string Keep a copy of the results on disk 7 4 Final Inspection 6 Verify that the interior and exterior of the system is clean and free from debris f Ensure all wires connected and bolts are properly tightened 8 Ensure the following the User Service and Calibration parameters are set properly on the controller default settings are in parenthesis LVD Param LVD1 Trip 42 00 V L VD1 Reset 48 00 V LVD2 Trip 42 00 V L VD2 Reset 48 00 V Batt Set alm Batt Disc Thr 10 A Batt Param Batt Float 54 00 V Batt Max Rech 50 A Batt Comp Comp Method OFF 9 Verify on the status menu that the system is functioning correctly with no alarms 10 Be sure to leave the site as orderly and neat as possible MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 59 8 Specifications The overall system specifications can vary depending upon the number of re
55. ndition 0 sec must exist for longer than the delay to be activated Delay between sensing of the alarm condition and Out R1y 6 Dly m activation of Output Relay 6 An alarm condition must exist for longer than the delay to be activated An alternate name alias can be assigned to the major Relay if desired Major An alternate name alias can be assigned to the Minor Relay if desired Minor Permanently change password PIN that permits PIN m 4 security Level 1 parameter changes limited access Permanently change password PIN that permits PIN 2 m security Level 2 parameter changes unlimited DIDO access Screen for entry of the active password PIN PIN m Before any changes can be made the correct pin 0000 for the desires security level must be entered Level O full read access Level 1 full read and limited write access Level 2 full read and write access The maximum rectifier communications response RectFailComm m time allowed before a communications failure is 1 min declared O sec The output relay energized if the rectifier Cfg Alm mt configuration differs from its stored configuration Minor This occurs if a rectifier is added after configuration The output relay that is energized or special rectifier alarm group n of N that occurs when a rectifier has been forced into the current limited mode The status will be ON if the rectifier has been forced into its current limited mode
56. ng correctly to the controller navigate through the menu and verify that the status for every rectifier in the system is Rect N FF OFF 2 Remove any rectifier and verify that you get a Minor alarm for rectifier 1 of n failure 3 Remove a second rectifier and verify that you get a Major alarm for rectifier 2 of n failure LVD Test 1 Enable the LVD s that are installed 2 Setthe LVD trip for each LVD to negative 56 Volts 3 The LVD should have dropped out opened Verify visually or by monitoring the voltage at the battery connection Also the minor alarm should be on 4 Set LVD Trip back to negative 42 Volts 5 The LVD should have closed Verify visually or by monitoring the voltage at the battery connection The minor alarm should be off 6 Ensure that the LVD parameters are set to desired value Battery Power Up 1 Monitor battery current and verify that it is 0 1 Amps 2 3 Set battery maximum recharge setting by determining the entire battery string capacity If the voltage is off adjust the S offset setting under the OEM menu and dividing by 10 hours This setting will recharge the battery in 10 hours Enter this value in the Max Batt Rech screen Monitor the battery current while closing the battery disconnects or installing open battery links Arcing can occur during this connection The voltage may drop if the maximum battery recharge current is exceeded The current should gradually decrease when the battery i
57. nt installation including but not limited to installation equipment travel expenses of an APC representative s and costs of installation material transportation expenses are not included as a part of this warranty Any replacement components or materials furnished under this warranty may be new or factory remanufactured THIS WARRANTY DOES NOT COVER CONSUMABLES OR PREVENTATIVE MAINTENANCE ITEMS REPAIR OR REPLACEMENT OF A DEFECTIVE PRODUCT OR COMPONENT THEREOF DOES NOT EXTEND THE ORIGINAL WARRANTY PERIOD Exclusions and Limitations This Warranty is extended to the first person firm association or corporation for whom the APC Product specified herein has been bought This Warranty is not transferable or assignable without the prior written permission of APC This limited warranty does not cover damage due to external causes including accident abuse misuse servicing not authorized by APC usage not in accordance with Product instructions failure to perform preventative maintenance and problems cause by use of parts and components not supplied by APC This limited warranty does not apply to Products from which the serial numbers have been removed or to conditions resulting from improper use accidents external causes including installation relocation of hardware service or modifications not performed by APC or its authorized service providers or operation outside the environmental parameters specified for the Product APC does not warrant tha
58. ntacts that are open when the breaker is on and closed when the breaker is off or tripped See Figure 3 7 2 for details Circuit breaker alarms can be monitored by attaching the other end of the alarm wire to the gray Wago connector on the Circuit Breaker LVD Expansion board Six different circuit breaker or groups of circuit breakers can be monitored in each bay Since the normally open contacts are monitored any tripped breaker will give an alarm 4 Install the alarm wire in the Wago connector on the expansion board Jumper the pins behind the Wago connectors based on what bay the circuit breaker are in Typical circuit breaker numbering is bay 1 Cir Bkr 49 54 Bay 2 Cir Bkr 55 60 Bay 3 Cir Bkr 61 66 and Bay 4 Cir Bkr 67 72 See Figure 3 2 6 for details 5 Reattach the circuit breaker cover panel Figure 3 7 2 Circuit Breaker Alarm Wiring MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 20 Telecom Fuse Installation 1 Remove the fuse s from the desired location s by pulling the fuse holder straight out of the fuse holder base 2 Install the fuse s by bolting the fuses s into the fuse holder 3 Re install the fuse holder by pushing the holder straight in 4 Connect the alarm wiring to the alarm terminal at the output of the fuse holder base 5 Connect the alarm wiring to the Fuse alarm Wago breakout board NOTE Fuse alarm contacts sense the voltage on the output of the fuse When the fuse is blown the outp
59. oard go to the bay to the left The ribbon cables on the right hand side of the board go to the bay to the right If there is an open Alarm Contact Bus connector no bay to the side of the unit the cable connector is left open and no further action is required However if the LVD Bus ribbon cable connector is open the pins nearest the connector will have to be jumpered Install the jumpers using Figure 3 2 5 as a guide to jumper orientation If a cable is installed remove the jumpers on the pins nearest the installed ribbon cable EAA D132 Controller CB Connect Mam Bay Only i i Bay 1 Bay Bay3 di Figure 3 2 5 Circuit Breaker LVD Expansion Board eng peuo ULTETy Alarm Contact Bus MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 8 Fuse Alarm Ribbon Cable Connections There is a 16 conductor ribbon cable if any bay has fuses installed This cable ties together the Wago breakout board in each bay with fuses The ribbon cable must connect all the Wago breakout boards together with one ribbon cable The idea is that each fuse will have one wire in the ribbon cable for the alarm Two fuse alarm wires should not be connected to the same fuse See Figure 3 2 6 for details Ribbon cable pin 1 is for Fuse 1 Ribbon cable pin 2 is for Fuse 2 etc Figure 3 2 6 Wago Fuse Alarm Breakout Board Ventilation The rectifier modules for this system have fans that provide front to rear airflow for internal cooling The MX28
60. oltage will be reduced the system limits the charging current to this programmable value Battery Temperature Battery temperature measured by the system Batt Temp Status Only controller at the optional battery temperature EE qm STATUS sensor probe Circuit Breaker 1 Alias An alternate name alias that can be assigned to Security Level 1 a circuit breaker if desired MODULES CIRBKR ALIAS Circuit Breaker 24 Alias An alternate name alias that can be assigned to Security Level 1 a circuit breaker if desired Cir Bkr 72 m MODULES CIRBKR ALIAS A8V MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 38 PARAMETER NAME DESCRIPTION DISPLAY SCREENS DEFAULT SETTINGS MENU LOCATION Circuit Breaker 1 Tripped An alarm that indicates Circuit Breaker 1 is Cir Bkr 1 Alm mit Security Level 1 tripped Major MODULES CIRBKR SET ALM Circuit Breaker 24 Tripped An alarm that indicates Circuit Breaker 24 is Security Level 1 tripped MODULES CIRBKR SET SES TEUER Ke ae ALM ajor Compensation High Knee The temperature compensation high knee is the Comp Hknee m Security Level 1 point above which there is no additional battery d r OC BATT COMP voltage compensation for further increases in temperature Compensation Low Knee The temperature compensation low knee is the Comp Lknee Security Level 1 point below which there is no additional battery BATT COMP voltage compensation for further decreases in temp
61. pment damage The battery cable connections are located at the top rear of the unit as shown in Figure 3 4 1 The battery positive return bus and battery negative 48V bus buses each provide four sets of 3 8 holes on one inch or 1 3 4 centers for connecting two hole battery cable lugs Connect the battery cables as applicable using 3 8 16 bolts not provided and tighten them with a torque wrench to 200 in lbs 23 N m AT EA ESE EE RENE EN Figure 3 4 1 Battery Cable Connection Locations MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 12 Battery Temperature Probe Installation The optional temperature probe is used to monitor the battery string temperature To get the most representative temperature measurement the probe should be placed in contact with a battery cell that is centrally located The probe should be placed directly in contact with the cell not the frame surrounding the cell Generally the cell cover can be used be careful not to allow the probe body to touch the terminals Remove the adhesive protection strip from the probe body and press the adhesive side of the probe on the battery cell cover See Figure 3 4 3 for details Plug the connector end of the temperature probe into J5 of the control unit backplane card Route the cable as required positioning the probe on the selected battery cell See Figure 3 4 2 for Details Figure 3 4 2 Battery Probe Connection Figure 3 4 3 Battery Probe
62. s nearing full charge MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 29 Circuit Breaker Fuse Test 1 For plug in circuit breakers Monitor alarm screen for circuit breaker alarm while shorting out each pair of alarm contacts using a pair of tweezers on the circuit breaker interface circuit board Verify proper voltage at the circuit breaker common bus 2 For fuses Monitor alarm screen for fuse alarm while removing fuses from each position Verify proper voltage at fuse common bus 3 Turn on fuses and circuit breakers as desired User Inputs 1 Change the user input to desired alarm via the controller for any input that will be used 2 Exercise the alarm by causing the input to change state 3 Verify the desired relay output on the controller module Output Relays 1 Change the alarm parameter to desired relay output via the controller for any relay output that will be used All alarm parameters are shipped as either major or minor but may be changed to any of 6 output relays 2 Program out put relay to desired major or minor alarm to complete programming 3 Exercise the output relay by causing the alarm to change state 4 Verify the desired relay output on the controller module Battery Temperature Compensation 1 Enable battery temperature compensation if desired 2 Ensure that battery temperature probe is connected to the system and attached to the battery 3 Verify that the system voltage is abo
63. s no sign of damage to the DC system Contact monitoring personnel or disable system alarms before servicing the unit This will allow the unit to be serviced without creating false alarms HIN System Visual and Safety Inspection 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 t is recommended that e Any jewelry rings or watches be removed while working on this equipment e Handles of all wrenches screwdrivers cutters and pliers are insulated 1 Ensure that the DC wiring is properly installed sized terminated and identified 2 Ensure that the AC wiring is properly installed sized terminated and identified 3 Ensure that the battery is properly connected to the System 4 Ensure that the DC output over current protection devices are adequate for the size of wiring installed 5 Ensure that the DC Positive is bonded to central office ground 48 volt system 6 Note the resistance of the ground bond 7 Note any currents flowing in the ground 8 Record ambient temperature 9 Verify that the battery polarity is correct 10 If battery disconnect devices are present note the following for each device a DC Voltage Rating b DC Current Rating c Interrupting Current Rating Battery Visual and Safety Insp
64. stored the Disable SYSTEM DIAG display toggles back to Disable after entry System Current The total system output current calculated as the Status Only sum of the individual rectifier output currents 145 8 A STATUS m System High Temperature The output relay energized if the System Sys HT Alm Alarm Temperature exceeds the system high Minor Security Level 1 temperature threshold SYSTEM SET ALM system High Temperature System Temperature is ambient temperature Sys IT TRE m Threshold measured inside the controller An alarm will be 70 0 C Security Level 1 reported if temperature is higher than the SYSTEM SET ALM temperature entered MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 43 PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS System High Voltage alarm The output relay energized if the System Voltage Sys HV Alm security Level 1 is above the System High Voltage threshold NO SYSTEM SET ALM System High Voltage oystem Voltage is bus voltage measured by the Sys HV Thr Threshold controller An alarm will be reported if voltage is sebo a V Security Level 1 higher than the voltage entered SYSTEM SET ALM System Low Temperature The output relay energized if the System Sys LT Alm m Alarm Temperature is below the System Low Minor Security Level 1 Temperature threshold SYSTEM SET ALM System Low Temperature System Temperature is ambient temper
65. t by links to APC web pages for specific countries and regions each of which provides customer support information o http www apc com support Submit customer support requests e Contact Local or regional APC Customer Support by telephone or e mail o For e mail addresses and local country specific customer support telephone numbers worldwide refer to http www apc com support contact o For e mail addresses and technical support telephone number of major APC regional customer support centers use the following list US and Canada 1 800 800 4272 Toll Free 1 800 800 4APC Worldwide 1 401 789 5735 US Toll Call e Contact the APC representative or other distributor from whom you purchased your APC hardware device or APC software application for information on how to obtain local customer support MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 64 I0 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 MX281200 2400 MX281200 4800 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 Warranty Procedure If initial physical
66. t the operation of any Product will be uninterrupted or error free Warranty service may not be performed if APC or other suppliers reasonably believe conditions at the Buyer s site represent a safety or health risk THERE ARE NO WARRANTIES EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE OF PRODUCTS SOLD SERVICED OR FURNISHED UNDER THIS AGREEMENT OR IN CONNECTION HEREWITH APC DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY SATISFACTION AND FITNESS FOR A PARTICULAR PURPOSE APC S EXPRESS WARRANTIES WILL NOT BE ENLARGED DIMINISHED OR AFFECTED BY AND NO OBLIGATION OR LIABILITY WILL ARISE OUT OF APC S RENDERING OF TECHNICAL OR OTHER ADVICE OR SERVICE IN CONNECTION WITH THE PRODUCTS THE FOREGOING WARRANTIES AND REMEDIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES THE WARRANTIES SET FORTH ABOVE CONSTITUTE APC S SOLE LIABILITY AND YOUR EXCLUSIVE REMEDY FOR ANY BREACH OF SUCH WARRANTIES APC S WARRANTIES RUN ONLY TO YOU AND ARE NOT EXTENDED TO ANY THIRD PARTIES INNO EVENT SHALL APC ITS OFFICERS DIRECTORS AFFILIATES OR EMPLOYEES BE LIABLE FOR ANY FORM OF INDIRECT SPECIAL CONSEQUENTIAL OR PUNITIVE DAMAGES ARISING OUT OF THE USE SERVICE OR INSTALLATION OF THE PRODUCTS WHETHER SUCH DAMAGES ARISE IN CONTRACT OR TORT IRRESPECTIVE OF FAULT NEGLIGENCE OR STRICT LIABILITY OR WHETHER APC HAS BEEN ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH DAMAGES
67. ternal alarm points AC service entrance and grounding schemes should all be checked and confirmed If batteries are to be mounted in a room separate from the power plant careful attention should be paid to battery cable voltage drop effects Environmental operating temperatures and ventilation cooling considerations should also be noted not just for the power system but also for all other equipment that may reside in the power room area MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 5 Mounting The box frame housing the MX28B components is self supporting but designed to be bolted to the floor of the housing structure Figure 3 2 1 shows the footprint of the box frame and the mounting points with dimensions shown in inches Consult the system design specifications to see if it is necessary to electrically isolate the frame from the floor structure This is required in many installations FRONT Figure 3 2 1 Floor Mounting Dimensions systems with multiple box frames are mounted with each frame touching side by side The side cover panels where two frames touch are removed so that bus work and control cables can pass between the frames Three holes are provided in center vertical rail of each side to allow the frames to be mechanically secured to each other if desired Power Bus Connections At the top of each bay there are 3 power buses that transfer the power from 1 bay to another The system is rated such that the ent
68. ty Level 1 battery temperature exceeds this value BATT SET ALM Battery High Voltage Alarm The output relay energized if the DC output Bett AV Alm m Security Level 1 voltage rises above the battery high voltage Minor BATT SET ALM threshold Battery High Voltage Threshold An alarm will be reported if temperature is lower Batt HV Thr m Security Level 1 than the temperature entered RO quu BATT SET ALM An alarm is generated if the DC output voltage rises above this value Battery Low Temperature The output relay energized if the Battery Batt LT Alm m Alarm Temperature drops below the battery Low Minor Security Level 1 Temperature threshold BATT SET ALM Battery Low Temperature Battery Temperature is temperature measured at Bett DE TAK Threshold Security Level 1 the battery probe An alarm is generated if the 0 0 i BATT SET ALM battery temperature drops below this value Battery Low Voltage Alarm The output relay energized if the DC output Batt LV Alm Security Level 1 voltage drops below the battery low voltage Minor BATT SET ALM threshold Battery Low Voltage Threshold An alarm is generated if the DC output voltage Pate IA Thr m Security Level 1 drops below this value 44 00 V BATT SET ALM Battery Maximum Recharge One of three parameters that control the DC Batt Max Rechm Current output voltage If Battery Current surpasses the 50 A Security Level 1 Maximum Battery Recharge Current the DC BATT PARAM output v
69. ut voltage is zero Only connect one fuse to each Wago connector in any bay GMT Fuse Installation Fuse holders that accommodate GMT fuses are located on the interface card mounted in the top left side of the unit Insert the fuse in the holder observing the tripped indicator is correctly oriented These fuse holders are only connected to 48VDC if the system has been purchased with the GMT fuse option This option supplies 48VDC to lugs on the interface card through a 50 Amp circuit breaker located in circuit breaker Position 1 The interface card provides fuse holders for eight fuses labeled F1 through F8 which can be used for small 48V DC loads Use the chart shown in Figure 3 3 to help determine what size fuses will carry the desired current Refer to Figure 3 9 1 for Interface board GMT fuse locations NOTE The controller will not report GMT Fuse failures in the MX28B1200 system Only telecom style fuses can be monitored Use GMT fuses only in non essential applications AMBIENT TEMPERATURE Figure 3 7 3 GMT Fuse Temperature De rating Chart MX28B1200 2400 MX28B1200 4800 48 VDC Users Manual Page 21 3 8 Load Connections Cable Size Considerations The DC load cable s should be sized sufficiently large to limit the voltage drop from the MX28B DC power plant 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
70. ve 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 MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 30 4 3 di m 4 5 Final Inspection Verify that the interior and exterior of the system is clean and free from debris Ensure all wires connected and bolts are properly tightened Ensure the following the User Service and Calibration parameters are set properly on the controller default settings are in parenthesis LVD Param LVD1 Trip 42 00 V LVD1 Reset 48 00 V LVD2 Trip 42 00 V LVD2 Reset 48 00 V Batt Set alm Batt Disc Thr 10 A Batt Param Batt Float 54 00 V Batt Max Rech 50 A Batt Comp Comp Method OFF Verify on the status menu that the system is functioning correctly with no alarms Be sure to leave the site as orderly and neat as possible MX28B1200 2400 MX28B1200 4800 48 VDC User s Manual Page 31 5 Operation 5 1 Technical Description The MX28B 1200 2400 Power System is designed to supply safe o4 VDC primary power through the use of up to 24 rectifier modules One rectifier bay may be added to increase the capacity to 48 rectifiers The MX28B 1200 4800 Power System is designed to supply safe 54 VDC primary power through the use of up to 24 rectifier modules Three rectifier bays may be added to increase the capacity to 96 rectifiers In conjunction with an external batter
71. wer Up EE 29 RECIF TES EE e EE DE EO RH HN FR ee ee 29 LVO TEEL SESDE GE E Ra ile TESTS RS M NN 29 Eater e EE 29 Circuit Breaker FUSE RE 30 Bic DUS GEE GE ER SE EE GE GE GE GE EE Ge GE ee EG GE GE YR NY 30 S P eig EIS at RD ie TETUR GR EE EE io EE OE Ee WRN HN 30 Battery Temperature Compensaiion sesse Ee Ee ER Ee ee Ee ee ee LL eek EER LL eek ee eke ee ee ee 30 4 3 mis Meo EE 31 5 OPERATION Gc aa e A i 32 5 1 TECHNICAL DESCRIPTION ri 32 5 2 RECTIFIER MANAGEMENT EE 32 AC dee 32 DE QUIDUL POWO E 32 FRO GUTICT alarms FGDOH ID O GE 32 5 3 SYSTEM MANAGEMERE rosea 9 500 010008 naar DE EN Ge OG ER EN YND DE GEND Ee OE 33 Arcs OIE CIPI I 33 System Vollad CONI cicca 33 SOA ETERO DE ER Ee De 33 System Status ana Alarm Ee le dee ses besk stes s tes eei ee Ee ee Ee GYD uie Ee Es ds 34 5 4 DE PISTRIEB FIG WEE 34 5 5 BATTERY MANAGEMENT se Eet ESEG GE GE SE OGE BO Ee GO ERG be Ee GE SO ESE Ee N OE EL GE EE RE eie Es 34 Battery Charging and Prote llOn sessie ie ie ee daU be be he he he he he ie he Fd 34 Battery Load ow Voltage DISCONNE EE 35 5 6 CONTROLS AND le erger 35 Front Panel User re 35 Parameter Locations Descriptions and Default Values ese ee ee ee ee ee YY ee YL Lu ee ee 36 Control Unit Menu Structure E 46 Fon ANE LED te ere 52 Dili ALARM OUTPUTS OUTPUT RELAYS herrera DL Ee 52 5 8 EXTERNAL ALARM INPUTS INPUT FSELAYS au seen ede See oe ede od ge de ed ie de FN AD 53 6 CREMO UE MONITORING reren 54 6 1 Basie sl el EEEE EE EEE
72. will be lower therefore the current will typically be higher If assistance is required to determine the necessary cables for the application contact your sales representative or APC Circuit Breaker Connections 1 to 50 Amps Connections for 1 to 50 amp DC loads require standard two hole lugs with holes for 10 screws 810 0032 on 5 8 centers and are located directly beside the corresponding circuit breaker See for details Circuit Breaker Connections 60 100 Amps Circuit breakers rated for 60 to 100 amp DC are twice as wide as the smaller breakers and therefore require two positions and a circuit breaker adapter kit The adaptor connects the two output lug positions to one lug Adaptors are available with studs for 10 32 nuts on 5 8 centers 4 20 nuts on 4 centers or 74 20 nuts on 1 centers The adaptor is installed directly beside the two positions the circuit breaker is mounted on using 10 screws provided in the kit The lugs not included with the kit fasten on to the adaptors studs using nuts and washers provided in the kit See for details Return Connections 1 100 Amps The load returns connect to the return buses located to the outside of the breaker connection points as seen in Error Reference source not found Each return bus provides 28 sets of threaded 10 32 holes on 5 8 centers fourteen sets of threaded 74 20 holes on 5 8 centers and fourteen sets of threaded 74 20 holes on 1 centers for connection of two
73. y string it will supply backup power as well The Power System Control Unit PSCU will monitor all MX28B functions and provides battery management including controlled battery recharge with temperature compensation and low voltage disconnect Integrated DC output distribution supports loads ranging from Amp all the way to 700 Amps Battery recharging temperature compensation and low voltage disconnect are included The controller can monitor up to 4 discrete external events with dry contact inputs 5 2 Rectifier Management AC Input Power The basic component of the power system is the rectifier module which rectifies utility AC into nominal 48 Volts DC Each rectifier module requires 208 220 240V AC MRF28H54BV or 277V ac MRF28H54BV50 single phase 50 60 Hz A breaker installed in a remote panel should individually protect each rectifier circuit DC Output Power The DC outputs of all the rectifiers in the system are connected to a common bus that is rated to carry the current of the entire system The rectifier modules will equally share the entire load independent of the PSCU The rectifiers will continue to provide DC power if the PSCU is removed or fails Rectifier alarms reporting The rectifier has numerous sensors inside the unit that monitor fan fail high temperature high low voltage etc These rectifier sensors trigger outputs that are monitored by the PSCU In addition rectifier current is measured inside each rectifier

American Power Conversion MX28B4800 User's Manual

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