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American Power Conversion MX28B400 User's Manual

1. Level Third Level Fourth Level Test Relay 5 Test Relay 6 Test Min Rly Test Maj Rly MX28B400 24V MOD MOD REC EM MODULES BATT RECT CONV CIR SET ALM PARAM I Rect CL Alm Rect Stdby Alm Rect FF Alm Rect RFA Alm REC Rect Fail Safe Rect Fail Comm REC Rect Desc e Rect Curr e Rect CL Rect Stdby e e e Rect 4 FF e e Rect RFA MX28B400 24V MOD MOD CON EM MODULES BATT CT CONV CIR SET ALM PARAM I Conv CL Alm Conv Stdby Alm FF Alm Conv CFA Alm Conv Voltage Conv Fail Safe Conv Fail Comm Conv Desc Conv CL Stdby MX28B400 24 VDC User s Manual Page 37 Level Second Level Third Level Fourth Level NV CIR BKR FUS
2. 28 400 24 Power System With Network Management 56 Manual User R 4 Table of Contents T SSAPETY 1 1 1 WARNING SYMBOLS 1 1 2 GENERAL PRECAUTIONS Lacie dere Ee EE E De Ee De ERR 1 27 INTRODUCTION 2 2 1 GENERALE INEOBMATION 221 dese Ide dad ra eb alate ete ores eiut 2 2 2 How To THIS MANUAL sete uc 4 3 INST AELATION urea isa uta ss acca 5 3 1 UNPAGKING EQUIPMENT 2422 24 teased 5 32 MECHANICAL INSTALLATION eng 5 Room 11 EU E escola 5 Denese Dn eo om 5 EIE PE PES 6 33 POWER CONNECTIONS dne ete end cred eoe Le oe due et 6 3 4 BATTERY CONNECIIONS abt elas hel 7 Planning the Battery installation tt eo 7 Connecting the Cables eR OR GER XE TR DOR ERG GER GRAIN E REOR EE IN nennen 7 Battery Temperature Probe Installation 22259500
3. 8 3 5 DC SYSTEM OROBNIDIBNO 2b aetate ea neqoe tassels 9 3 6 DC POWER OUTPUT OVER CURRENT eene 10 Breakers id itcr 10 Plug in Circuit Breaker Installation eese 12 Load Cable Size COnSIderatlOl 12 Circuit Breaker Connections 1 to 50 20000000000000 13 Circuit Breaker Connections 60 100 2 200990 8 13 GMT Fuse Ep 14 2 7 MONITORING AND RELAY OUTPUT CONNECTIONS 100 14 Ri ER 14 Smart Cable 9 Connection 14 RJ45 Ethernet Connector axis 15 Relay Qutp t 15 3 8 EXTERNAL ALARM INPUT CONNECTIONS 16 3 9 RECTIFIER MODULE INSTAEENTION 5 cn ticae cede a e i ek 17 3 10 INITIAL POWER UP AND GHEGCKODT cce ctt eS Eee eR e E EE eo eh ER reo t EX E eS EE eee EX De eR EE EORR 17 3 11 SYSTEM PARAMETERS VERIFICATION ADJUSTMENT 1 14 nnne nnne nnne 18 312 SYSTEM POWER UP e eee 19 4 OPERATION
4. 20 4 1 TECHNICAL DESCRIP 20 4 2 RECTIFIER MEME Na 20 no POWEF 20 IDEs Qe Ti seu mc rd 20 MX28B400 24 VDC User s Manual Page ii Rectifier alarms ade Haa gu ue 20 4 3 SYSTEM MANAGEMENT teat 21 System Output Capacity 21 System 21 System OUITelll 21 System Status and Alarm Reporting esses 21 4 4 DOJBISTRIBUTIDNO o o se pe ue 22 4 5 BATTERY MANAGEMENT 2 odi dio dini ndi nti nd md odio odia ndn ndi nonu odio 22 Battery Charging and 22 Battery Temperature nns 22 Low Voltage 23 4 6 GONTROESAND INDICATORS redeo etie 23 Front Panel Ser tacta 23 Parameter Locations Descriptions and Default 2 2 2 2 000000000050000000 24 Control Unit SIFUGTDEO
5. ve tese etw 34 Front Panel LED Indicators x ox tee A 40 4 7 ALARM OUTPUTS OUTPUT REDAYS eiit rtis 41 4 8 EXTERNAL ALARM NPUTS INPUT RELAYS 2 05 cueccus cuseensccusecuaceueecesccubeeuaceuedeneccusdeusecuteeue 41 5 REMOTE 4 22 1 1 111 11 4 6 42 51 S mA hom eer s 42 5 2 PHYSICAE CONNEGOTIONS dtd ent esee e e eine ea rece e c E ers 42 5 3 COMMAND AND MONITORING PROTOCOL 42 6 SPECIFICATION S 43 Pn Se hr etin ee ce bt E 43 1MRF28H27BV Rectifiers eese 43 HMERE2Z2OFHZEKBVOUTIBOITIBES tcu tet Ee bna be CE E 43 6 2 OUTPUT WITH EITHER RECTIFIER 44 6 3 CONTROLS AND INDICATORS tiene ato ob 44 RECUS ee aN epu Ae I CIA nA 44 Power Shelf Control EPI EIE ERO uo EO 45 6 4 MECHANICA p 46 6 5 ENVIRONMENTAL n dte erii eil ID iiA md 46 6 6 6 d tos ct ome dass 46 7 APC WORLDWIDE CUSTOM
6. Time SYS SYS OUT OUT RLY IN R RLY MAP ALIAS ct T T a pM IK MX28B400 24 VDC User s Manual Page 35 Level Third Level Fourth Level Out Rly 6 Alm e Out Rly 1 Dly hd Out Rly 2 Dly 2 Out Rly 3 Dly Out Rly 4 Dly i Out Rly 5 Dly Out Rly 6 Dly SYS 0UT AP ALIAS Out Rly 1 e Out Rly 2 Out Rly 3 Out Rly 4 e Out Rly 5 Out Rly 6 Relay Minor Relay Major e SYS SYS IN LY IN RLY DIAG RLY MAP ALIAS In Rly 1 Alm In Rly 2 Alm e In Rly 3 Alm e In Rly 4 Alm SYS IN AP ALIAS In Rly 1 In Rly 2 In Rly 3 In Rly 4 SYS LY DIAG Store Cfg e e Lamp Test Test Relay En Test Relay 1 Test Relay 2 Test Relay 3 Test Relay 4 MX28B400 24 VDC User s Manual Page 36
7. 7 SHUNT CUSTOMER RETURN BUS 27V BLACK RED BLACK os pz BLACK a RED paf GREEN YELLOW owse1s lt e E RECTIFIER POSITION 1 RECTIFIER POSITION 2 Figure 2 1 2 MX28B 400 24 Vdc System Wiring Diagram with Battery LVD MX28B400 24 VDC Manual Page 3 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 Safety First Safety symbol description and general precautions Introduction i Brief system preview and explanation of manual usage Installation How to unpack install and commission the equipment for initial use BEES NE Specifics of controls settings and indicators used to operate the unit Remote Special remote monitoring and control features described with Monitoring references to information on auxiliary equipment Specifications EE Power plant and rectifier specifications APC Worldwide How to contact APC for customer support Customer Support Warranty Equipment warranty terms and conditions MX28B400 24 VDC User s Manual Page 4 3 Installation 3 1 Unpacking Equipment Remove equipment from packing material and i
8. Compensation Temperature Temperature compensation coefficient Coefficient between low knee and high knee in Security Level 1 mV cell C Compensation equals zero BATT COMP at 25 C Control Unit Revision Hardware revision level of the control Cntrl Rev Status Only unit This parameter cannot be changed 000002 SYSTEM SETUP Conv HV Alm The output relay energized if the Conv HV Alm m Converter Voltage nominal 48 Vdc is Minor above the Converter High Voltage threshold Conv HV Thr Converters are an optional device used Conv HV Thr m to convert 24 Vdc to 48 Vdc 58 00 V Converter Voltage is converter bus voltage measured by the controller An alarm will be reported if voltage is higher than the voltage entered Conv LV Alm The output relay energized if the Conv LV Converter Voltage nominal 48 Vdc is below the Converter Low Voltage threshold Conv LV Thr Converters are an optional device used to convert 24 Vdc to 48 Converter Voltage is converter bus voltage measured by the controller An alarm will be reported if voltage is lower than the voltage entered Date Internal system calendar date Used as Date m Security Level 1 a date stamp in the event log DEC 16 1999 SYSTEM DATE Status Only This parameter cannot be changed 000255 SYSTEM SETUP Fahrenheit Scale Enables selection of Fahrenheit or Fahrenheit m Security Level 1 Celsius temperature scale Fahrenheit OFF SYSTEM SETUP
9. The output relay energized if there is a conflict between the commanded and sensed positions of the LVD contactor Generally the contactor is open when it should be closed The output relay energized if there is a hardware failure in the system temperature monitoring function The output relay energized if there is a hardware failure in the system voltage monitoring function The Output Relay that is energized when an external contact closure or opening at the Input Relay 1 connection changes state The Output Relay that is energized when an external contact closure or opening at the Input Relay 4 connection changes state An alternate name alias can be assigned to Input Relay 1 if desired An alternate name alias can be assigned to Input Relay 1 if desired MX28B400 24 VDC User s Manual DISPLAY SCREENS DEFAULT SETTINGS us Hw Batt Almm4 Minor Batt Almm Minor In Rly 4 m Input Relay 4 Page 28 Parameter Locations Descriptions and Default Values PARAMETER NAME MENU LOCATION Lamp Test Security Level 1 SYSTEM DIAG 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 Leve
10. 1 CAUTION Rectifier fan inlet filters are available for dusty or hostile rectifier shutdown due to over temperature and produce power plant failure 3 10 Initial Power Up and Checkout Before initiating power up and checkout ensure that the following conditions exist 1 Make sure that the external circuit breaker protecting the cables from the battery to the power plant is turned OFF the battery cables should be connected to the power plant but the battery should not be connected 2 Make sure that all load circuit breakers are turned OFF including the one feeding the GMT fuses if the unit has the GMT fuse option 3 Verify that all rectifiers have been installed MX28B400 24 VDC User s Manual Page 17 4 Apply ac Power Turn on the circuit breakers that supply ac power to the rectifiers in the MX28B power plant The main screen should appear on the control unit display see Figure 4 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 4 6 1 that extends beyond 16 characters to the right of the S in ALARMS can viewed the control unit display by using the scrolling controls refer to Section 4 6 for operation of the control unit NOTE When ac power is initially applied there is a 60 second period during which no alarms are reported source Keep the a
11. 23 inch rails MX28B400 24 VDC User s Manual Page 5 Ventilation The rectifier modules for this system have fans that provide front to rear airflow for internal cooling The MX28B housing should mounted such that there is free airflow to the front top and bottom of the unit Refer to Section 6 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 power plant requires the supply of nominal 230 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 1MRF28H27BV rectifier is designed for the standard 208 220 240 Vac input service while the 1 28 27 50 is used for the 277 Vac input The ac wiring from the 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 right rear of the MX28B housing is provided with two one inch conduit entry holes and an access cover Inside a t
12. DATE System temperature measured within the Sys Temp control unit 26 7 Sys Voltage 27 00 V Test Maj Rly m System output voltage measured between the power plant 24V and return buses Setting this parameter to ON de energizes the Major Relay and turns on the MAJ LED on the control unit front panel In normal operation Major Relay is energized so that when a loss of 24 Vdc power occurs the relay will change state Setting this parameter to ON energizes the Minor Relay and turns on the MIN LED on the control unit front panel Setting this parameter to ON energizes Relay 1 and turns on the ALM1 LED on the control unit front panel Setting this parameter to ON energizes Relay 6 and turns on the ALM6 LED on the control unit front panel This parameter must be set to Enable to permit the eight output relays to be manually tested otherwise the state of the relays will be per system conditions Internal system clock time 24 hour format Used as a date stamp in the event log MX28B400 24 VDC User s Manual Test Min Rly m OFF Test t Relay 1 m OFF lay En m Disable Page 33 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 ti
13. OFF displays readings in C Firmware Version Version number of the control unit FW Version Status Only firmware 000192 SYSTEM SETUP NOTE Actual firmware version number displayed is the current version as of the date of manufacture This parameter cannot be changed MX28B400 24 VDC User s Manual Page 27 Parameter Locations Descriptions and Default Values PARAMETER NAME MENU LOCATION Fuse 1 Alias Security Level 1 MODULES GMT ALIAS Fuse 1 8 Alm Security Level 1 MODULES GMT SET ALM Hardware Battery Current Alarm Security Level 2 SYSTEM SET ALM Hardware Battery Temperature Alarm Security Level 2 SYSTEM SET ALM Hardware LVD Alarm Security Level 2 SYSTEM SET ALM Hardware System Temperature Alarm Security Level 2 SYSTEM SET ALM Hardware System Voltage Alarm Security Level 2 SYSTEM SET ALM Input Relay 1 Security Level 1 SYSTEM IN RLY RLY MAP Input Relay 4 Security Level 1 SYSTEM IN RLY RLY MAP Input Relay 1 Alias Security Level 1 SYSTEM IN RLY ALIAS Input Relay 4 Alias Security Level 1 SYSTEM IN RLY ALIAS DESCRIPTION Not used in this power system Fuse 1 Alias mt 27V Not used in this power system Fuse 1 Alm m Major The output relay energized if there is a hardware failure in the battery current monitoring function The output relay energized if there is a hardware failure in the battery temperature monitoring function
14. 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 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 key is pressed again the M changes back to m and the new entry is stored in memory MX28B400 24 VDC Manual Page 23 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 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 leve
15. is energized or Rect CL Alm m Security Level 1 special rectifier alarm group n of N that n of N MODULES RECT SET ALM occurs when a rectifier has been forced into the current limited mode Rectifier Current Limit Alarm The status will be if the rectifier has Rect 1 CL Status been forced into its current limited mode Status Only NOTE This information can be MODULES RECT INFO viewed for each rectifier installed by using the horizontal arrow keys Rectifier Current Output Status A display of the dc output current for the Rect 1 Curr Status Only individual rectifier NOTE This 24 9 MODULES RECT INFO information can be viewed for each rectifier installed by using the horizontal arrow keys Rectifier Description Displays the model number of the Rect 1 Desc Status Only installed rectifier NOTE This MRF28H27 MODULES RECT INFO information can be viewed for each rectifier installed by using the horizontal arrow keys Rectifier Fail 1 of N Alarm The output relay energized if Rectifier Almm Security Level 1 1 of N alarm occurs This is Minor SYSTEM SET ALM special rectifier alarm group that signifies that one rectifier has at least one alarm condition Rectifier Fail 2 of N Alarm The output relay energized if Rectifier 20fN Almm Security Level 1 Fail 2 of N alarm occurs This is a special Major SYSTEM SET ALM rectifier alarm group that signifies that more than one r
16. itself or the alarm will never clear Screens for making the assignments are located at SYSTEM IN RLY RLY MAP 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 8 MX28B400 24 VDC User s Manual Page 41 5 Remote Monitoring 5 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 power system in the form of a small Quick Start Guide and a CD The CD contains electronic copies of User s Manuals along with the necessary software utilities to support the management function 5 2 Physical Connections The management card has a RJ 45 connector to support a TCP IP protocol over a 10 100 BaseT 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 Procomm 5 3 Command and Monitoring Protocol Refer to the User s Guides and associated documentation provided on the management card CD for the details on installation and use of the various communication prot
17. only if the corresponding NC C contacts are going to be used EXTERNAL J4 TERMINAL ALARM DESIGNATION USER ALARM NOTES INPUT NO NC C 1 NO1 NC1 C1 2 NO2 NC2 C2 3 NO3 NC3 C3 4 NO4 NC4 C4 Figure 3 8 2 External Alarm Input Connections MX28B400 24 VDC Manual Page 16 3 9 Rectifier Module Installation installed incorrectly Before rectifier installation ensure proper battery WARNING Rectifier output circuits would be damaged if battery were 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 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 Fasten the rectifier in place with the rectifier retaining screw included in literature 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 environments Failure to periodically check and clean filters can lead to
18. relays activates no additional relays MX28B400 24 VDC User s Manual DISPLAY SCREENS DEFAULT SETTINGS Lamp Test m OFF Model m MX28B 400 24V R Gain m 1 000 V Offset mt 0 000 V 5 Gain m 1 000 A OEM S Offset m 0 0 A ut Rly 1 Alm m Ignore Out Rly 6 Alm m Ignore Page 29 Parameter Locations Descriptions and Default Values PARAMETER NAME MENU LOCATION Output Relay 1 Alias Security Level 1 SYSTEM OUT RLY ALIAS Output Relay 6 Alias 1 SYSTEM OUT RLY ALIAS 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 MX28B400 24 VDC User s Manual DESCRIPTION DISPLAY SCREENS DEFAULT SETTINGS An alternate name alias can be assigned to Output Relay 1 if desired An alternate name alias can be assigned to Output Relay 6 if desired Delay between sensing of the a
19. Alm Minor m Batt HT Thr m 70 0 Page 25 Parameter Locations Descriptions and Default Values PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Battery Low Temperature The output relay energized if the Battery Batt LT Alm m Alarm Temperature drops below the battery Minor Security Level 1 Low Temperature threshold BATT SET ALM Battery Low Temperature Battery Temperature is temperature Batt LT Thr m Threshold Security Level 1 measured at the battery probe An alarm 0 0 BATT SET ALM is generated if the battery temperature drops below this value Battery Low Voltage Alarm The output relay energized if the dc Batt LV Alm m Security Level 1 output voltage drops below the battery Minor BATT SET ALM low voltage threshold Battery Low Voltage Threshold An alarm is generated if the dc output att LV Thr m Security Level 1 voltage drops below this value 22 00 V BATT SET ALM at Battery Maximum Recharge One of three parameters that control Batt Max Current dc output voltage If Battery Current 50 Security Level 1 surpasses the Maximum Battery BATT PARAM Recharge Current the dc output voltage will be reduced the system limits the charging current to this programmable value Battery Temperature Battery temperature measured by the Batt Temp Status Only system controller at the optional battery 25 STATUS temperature senso
20. Connection Locations MX28B400 24 VDC User s Manual Page 7 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 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 Remove the adhesive protection strip from the probe body and press the adhesive side of the probe on the battery cell cover Figure 3 4 2 Battery Temperature Probe Installation MX28B400 24 VDC User s Manual Page 8 3 5 SYSTEM GROUNDING The return bus for the power plant must be connected to the Central Office Ground The left end of the return bus provides a pair of threaded 3 8 16 holes on 1 inch 25 4 m centers for connection of a two hole lugged cable to the Master Station Ground Details for this connection should be provided in the site electrical grounding plans Figure 3 5 1 DC Ground Connection Point MX28B400 24 VDC User s Manual Page 9 3 6 DC Power Output Over Current Protection DC Circuit Breakers A standard 24 position plu
21. E SET ALM ALIAS Cir Bkr 1 Alm Cir Bkr 2 Alm Cir Bkr 3 Alm Cir Bkr 22 Alm e Cir Bkr 23 Alm Cir Bkr 24 Alm LM ALIAS Gir 1 Cir Bkr 2 e Cir Bkr 3 Cir Bkr 22 e e Cir Bkr 23 e e Cir Bkr 24 e MOD FUS KR FUSE LVD SET ALM ALIAS FUSE 1 Alm FUSE 2 Alm FUSE 3 Alm FUSE 14 m e FUSE 15 m FUSE 16 Alm 05 SE ALIAS FUSE FUSE 2 FUSE 3 MX28B400 24 VDC User s Manual Page 38 Level Third Level Fourth Level e e e e e e e e e e e e e FUSE 14 FUSE 15 e FUSE 16 MOD LVD MT LVD SET ALM PARAM LVD 1 Option 1 LVD 2 Option 2 MOD LVD t LM PARAM LVD 1 Trip e LVD 1 Reset 2 Trip e 2 Reset MX28B400 24V BAT ES PIN SET ALM PARAM Batt Disc Thr e Batt Di
22. ER 47 8 LIMITED PRODUCT 2 0 0 1 1411 1 48 MX28B400 24 VDC User s Manual Page iii Revision History Revision Date By Description 990 1809 Rev 1 02 MAR 2004 BET Preliminary Release Table of Figures FIGURE 2 1 1 MX28B 400 24 VDC POWER PLANT 2 FIGURE 2 1 2 MX28B 400 24 VDC SYSTEM WIRING DIAGRAM WITH BATTERY LVD 3 FIGURE 3 4 1 BATTERY CABLE CONNECTION 2 502 54 neta euo ete T FIGURE 3 4 2 BATTERY TEMPERATURE PROBE INSTALLATION 8 FIGURE 3 5 1 DC GROUND CONNECTION gt 55 9 FIGURE 3 6 1 DC DISTRIBUTION FRONT COVER 10 FIGURE 3 6 2 CIRCUIT BREAKER Fete p rite eim a ants 11 FIGURE 3 6 3 INSTALLATION OF CIRCUIT BREAKERS 4 ren 12 FIGURE 3 6 4 STANDARD LUG FOR 1 50 BREAKERS 13 FFIGURE 3 6 5 ADAPTOR AND LUGS FOR 60 100 AMP BREAKERS e 14 FIGURE 3 7 LEINTBREXCE BOARD puien n 15 FIGURE 3 7 2 OUTPUT RELAY CONNEC 16 FIGURE 3 8 1 EXTERNAL ALARM INPUT DEFINITION 16 FIGURE 3 8 2 EXTERNAL ALARM INPUT CONNECTIONS 16 FIGURE 4 6 L MENU TOP LINE pa d e anh a ee e
23. MX28B400 24 VDC User s Manual Page 1 2 Introduction 2 1 General Information 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 24 Vdc power plant It is configurable in such a manner that it will support most typical applications within the specified current ranges 400 amperes without special application engineering or assistance Distribution is included for up to 24 plug in circuit breakers These circuit breakers can be 1 to 100 amps with 60 100 amp breakers requiring two positions and a circuit breaker adapter kit An optional low voltage disconnect LVD can be provided on either the battery or the load side An MX28B is shown in Figure 2 1 1 A system wiring diagram is shown in Figure 2 1 2 Al AN obw 444 Figure 2 1 1 28 400 24 Vdc Power Plant with circuit breaker cover removed MX28B400 24 VDC Manual Page 2 27 BUS DA a u CABLE FOR OM 3036 2 24 0 90130 CONNECTS 11 ON PWB CUSTOMER 5 0 91029
24. P 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 MX28B400 24 VDC User s Manual Page 24 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 Item 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 Battery High Temperature Alarm Security Level 1 BATT SET ALM Battery High Temperature Threshold Security Level 1 BATT SET ALM Battery High Voltage Alarm Security Level 1 BATT SET ALM DESCRIPTION Power plant address or identification first line Power plant address or identification second line Power plant address or identification third line Display of up to 16 active alarms a typical alarm screen is
25. R WHETHER APC HAS BEEN ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH DAMAGES MX28B400 24 VDC User s Manual Page 48
26. SIZE RATING 1A FFA 0014 None 3A FFA 0015 None 5A FFA 0016 None 10A FFA 0017 None 20A FFA 0018 None 30A FFA 0019 None 40 0020 50 FFA 0025 None 60A FFA 0021 1 10 studs on 5 centers 60A FFA 0021 2 10 studs on 94 centers 60A FFA 0021 3 studs on 1 centers 70A FFA 0022 1 10 studs on centers 70 0022 2 10 studs centers 70 0022 3 studs on 1 centers 80A FFA 0023 1 10 studs on 5 centers 80A FFA 0023 2 10 studs 94 centers 80 A FFA 0023 3 studs on 1 centers 100 A FFA 0024 1 10 studs centers 100A FFA 0024 2 10 studs on 94 centers 100A FFA 0024 3 studs 1 centers Figure 3 6 2 Circuit Breaker Kits MX28B400 24 VDC User s Manual Page 11 Plug in Circuit Breaker Installation alarm terminals with the alarm terminal board to avoid breaker terminal CAUTION During circuit breaker installation carefully align the breaker 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 6 3 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 breake
27. atches be removed while working on this equipment e Handles of all wrenches screwdrivers cutters and pliers should be insulated Planning the Battery installation The battery cable s should be sized sufficiently large to limit the voltage drop from the power plant to the battery during charging per system design requirements The cable s must also carry the full load current during battery operation If 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 positive line located at the battery end to protect the cables from the battery to the power plant The power plant can monitor auxiliary contacts from this breaker Connecting the Cables connections to the power plant Incorrect connection could cause severe WARNING Make certain that the battery polarity is correct when making equipment damage The battery cable connections are located at the top left rear of the unit as shown in Figure 3 4 1 The battery positive and battery negative connection buses each provide two sets of threaded 3 8 16 holes on one inch 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 Ibs 23 N m POS BATTERY Figure 3 4 1 Battery Cable
28. c input enclosure cover in place when the system is WARNING The power is supplied from nominal 220Vac 50 60 Hz operational or energized 3 11 System Parameters Verification Adjustment The MX28B system control unit is delivered with pre programmed parameter default settings A complete listing and description of all system configuration parameters as well as displayable system status and information is provided in Section 4 6 Users should read Section 4 1 to gain an understanding of and how to use the operational features provided by the MX28B power plant As a minimum the following parameters should be verified and adjusted if required before connecting batteries or loads to the power plant 1 Battery Float Voltage default 27 00Vdc Check the manufacturer s recommendation for the batteries being used in the system 2 Battery Maximum Recharge Rate default 12A 3 System Voltage measurement 27 00Vdc This is a measurement by the system of the output bus voltage 4 LVD Option default Enable If the MX28B does not have LVD installed this should be changed to Disable 5 Rectifier Information Check the rectifier information displays to verify that all rectifiers installed can be viewed on the control unit display and that no rectifier alarms are active Section 4 6 provides location information for these parameters and how to make changes if required MX28B400 24 VDC User s Ma
29. d by APC or its authorized service providers or operation outside the environmental parameters specified for the Product APC does not warrant that 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 IN NO 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 O
30. e free from defects in materials and workmanship for a period of two 2 years from the date of shipment Warranty Procedure If initial physical 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 re
31. ectifier has at least one alarm condition Rectifier Fail Safe Voltage Rectifier default output voltage if Security Level 1 communication with the control unit fails MODULES RECT PARAM Rec Rectifier Fan Fail Alarm The output relay that is energized or Security Level 1 special rectifier alarm group n of N that MODULES RECT SET ALM occurs when a rectifier fan has failed Rectifier Fan Fail Alarm Status The status will be if the rectifier fan Status Only has failed NOTE This information MODULES RECT INFO can be viewed for each rectifier installed by using the horizontal arrow keys Rectifier Fault Alarm RFA The status will be the rectifier output Rect 1 RFA Status has failed NOTE This information OFF Status Only can be viewed for each rectifier MODULES RECT INFO installed by using the horizontal arrow keys Rectifier RFA Alarm The output relay that is energized or Rect RFA Alm m Security Level 1 special rectifier alarm group n of N that n of N MODULES RECT SET ALM occurs when a rectifier output has failed MX28B400 24 VDC User s Manual Page 31 Parameter Locations Descriptions and Default Values PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Rectifier Standby Alarm The output relay that is energized or Rect Stdby Almm Security Level 1 special rectifier alarm group n of N that n of N MODULES RECT SET ALM occurs when the control unit i
32. ee internal sensors is above 90 C Current Limit LED On when rectifier is in current limit Overvolts LED On when rectifier is above 29 5 Vdc Must be powered down to reset 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 and MX28B400 24 VDC User s Manual Page 44 Test Point Rectifier Current can be measured with a voltmeter between COM I Current is 10A V multiplied by test point voltage Float Boost Equalize Switch Used to Control voltage on systems without a PSCU Float Trim Pot The float pot is used to adjust the default float voltage 27 2 Vdc Boost Equalize Trim Pot The boost equalize pot is used to adjust the default boost equalize voltage 28 8 Vdc Power Shelf Control Unit Major Red On when Major Relay is de energized Minor Yellow On when Minor Relay is energized Normal Green On when no alarms are active ALM 1 Red On when Output Relay 1 is energized ALM 2 Red On when Output Relay 2 is energized ALM 3 Red On w
33. erminal strip for ac input power connection and a separate Earth Ground bar for connection of the safety ground wire s are provided The terminal block s is labeled as Position 1 through Position 4 with each position having inputs designated L1 and L2 N for connection of the 2 ac wires Positions 1 4 correspond to the rectifier shelf positions from left to right The suggested wire size is 10 AWG rated at 90 or higher however the ambient temperature and number of wires in a conduit must also be considered in accordance with NEC requirements lt 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 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 Hz source Keep the ac input enclosure in place when the system is WARNING The MX28B power plant is supplied from a nominal 230Vac 60 operational or energized MX28B400 24 VDC User s Manual Page 6 3 4 Battery Connections WARNING Hazardous energy levels are present on bare conductors in the 24Vdc 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 e Any jewelry rings or w
34. f voltage is higher than the SYSTEM SET ALM voltage entered System Low Temperature The output relay energized ifthe 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 Sys LT Thr m Threshold temperature measured inside the 0 0 Security Level 1 controller An alarm will be reported if SYSTEM SET ALM temperature is lower than the temperature entered System Low Voltage Alarm The output relay energized if the System Sys LV Alm m4 Security Level 1 Voltage is below the System Low Voltage Minor SYSTEM SET ALM threshold System Low Voltage Threshold System Voltage is bus voltage measured Sys LV Thr m Security Level 1 by the controller An alarm will be 25 00 V SYSTEM SET ALM reported if voltage is lower than the voltage entered MX28B400 24 VDC User s Manual Page 32 Parameter Locations Descriptions and Default Values PARAMETER NAME DESCRIPTION DISPLAY SCREENS DEFAULT SETTINGS MENU LOCATION System Temperature Status Only STATUS System Voltage Status Only STATUS Test Major Relay Security Level 1 SYSTEM DIAG Test Minor Relay Security Level 1 SYSTEM DIAG Test Relay 1 Security Level 1 SYSTEM DIAG Test Relay 6 Security Level 1 SYSTEM DIAG Test Relay Enable Security Level 1 SYSTEM DIAG Time Security Level 1 SYSTEM
35. for 1 to 50A breakers NOTE Load return lugs are connected to the front of the return bus to prevent interfering with the top cover of the unit Circuit Breaker Connections 60 100 Amps Connections for 60 to 100 amp dc loads 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 10 32 nuts on 34 centers 74 20 nuts on 1 centers The adaptor is installed directly above 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 adaptor s studs using nuts and washers provided in the kit MX28B400 24 VDC User s Manual Page 13 The load returns connect to the return bus located just above and rearward of the breaker connection points as seen in Figure 2 1 1 The return bus provides 24 sets of threaded 10 32 holes 5 8 centers and four sets of threaded 74 20 holes centers for connection of two hole lugs on load return wires Load Connections should be made as shown in fFigure 3 6 5 A fFigure 3 6 5 Adaptor and lugs for 60 100 Amp breakers GMT Fuse Option The customer interface card shown in Figure 3 7 1 is used in the 48V systems to connect loads smaller than 15 A This option is not available in the 24 V system The interface ca
36. g in circuit breaker tier provides 24 Vdc 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 The breaker tier is connected at its center to the 24 Vdc bus and each side has a current capacity of 300A It is therefore necessary to balance the load on the power plant to avoid overloading 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 24 single 1 50 Amp or up to 12 double 60 100 Amp breakers may be installed Figure 3 6 1 shows the power plant s distribution section with the front cover removed avs a p s Kee Figure 3 6 1 DC Distribution Front Cover Removed 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 centers 74 20 nuts 1 centers circuit breaker kit includes all necessary mounting hardware Available plug in circuit breakers and circuit breaker kits are shown in Figure 3 6 2 MX28B400 24 VDC Manual Page 10 ADAPTOR
37. hen Output Relay 3 is energized ALM 4 Red On when Output Relay 4 is energized ALM 5 Red On when Output Relay 5 is energized ALM 6 Red On when Output Relay 6 is energized MIN Red On when Minor Relay is energized MAJ Red On when Major Relay is de energized This will allow the Major to activate even when all power is lost MX28B400 24 VDC User s Manual Page 45 6 4 Dimensions 15 75 high x 23 wide x 17 5 deep Weight Housing 85 Ib Rectifier each 11 Ib Color Dawn Gray Mounting Front or mid mounting on standard 23 inch rails 6 5 Environmental Ambient Temperature Operating 45 C to 55 65 C with reduced power output Storage 45 to 85 C Humidity Operating 0 85 RH non condensing Storage 0 9590 RH non condensing Altitude Operating 3000 m 9840 ft Storage 10000 m 39370 ft 6 6 Compliance Safety UL 1950 Third Edition EMC FCC Part 15 Class A MX28B400 24 VDC User s Manual Page 46 7 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 Use an 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 Corpora
38. l 2 OEM OEM R Offset Security Level 2 OEM 5 Gain Security Level 2 OEM OEM 5 Offset Security Level 2 OEM Output Relay 1 Alarm Security Level 1 SYSTEM OUT RLY RLY MAP Output Relay 6 Alarm Security Level 1 SYSTEM OUT RLY RLY MAP DESCRIPTION Setting Lamp Test to will turn on the MAJOR MINOR NORMAL MAJ and MIN LEDs on the control unit front panel 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 L VD 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 power plant 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 activates no additional relays Output Relay 6 Alarm can be mapped to activate other output
39. l password reverts to level 0 and 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 ALM6 MIN and MX28B t STATUS ALARMS SYSTEM MODULES BATT PIN OEM Figure 4 6 1 Menu Top Line Parameter Locations Descriptions and Default Values The location description and factory programmed default value for each of the 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 parameters that can be accessed in this category starting from the main menu screen do the following 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 RLY 4 Press the down arrow key once the cursor will be cycling below RLY MA
40. l remain open until ac power is restored to the system and the bus voltage reaches the level defined by the LVD 7 Reset Voltage variable NOTE The LVD is normally energized and must be commanded to open This assures that the LVD will remain closed even if the controller fails or is removed 4 6 Controls and Indicators 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 gt right 0 up and 2 down arrow keys located on the front panel The selected item on the display is identified by the cursor cycling beneath its characters The 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 right corner of the display If a security level higher than the one presently set is required to modify the parameter 5 is displayed instead of m 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
41. larm condition and activation of Output Relay 1 Analarm condition must exist for longer than the delay to be activated Delay between sensing of the alarm condition and activation of Output Relay 6 Analarm condition must exist for longer than the delay to be activated An alternate name alias can be Relay Major assigned to the major Relay if desired m Major An alternate name alias can be Relay Minor assigned to the Minor Relay if desired m Minor Permanently change password PIN that permits security Level 1 parameter changes limited access Permanently change password PIN that permits security Level 2 parameter changes unlimited access Screen for entry of the active password PIN Before any changes can be made the correct pin for the desires security level must be entered Level 0 full read access Level 1 full read and limited write access Level 2 full read and write access The maximum rectifier communications response time allowed before a communications failure is declared RectFailComm m 1 min The output relay energized if the rectifier configuration differs from its stored configuration This occurs if a rectifier is added after configuration Rect Cfg Alm m Minor Page 30 Parameter Locations Descriptions and Default Values PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Rectifier Current Limit Alarm The output relay that
42. lure the individual rectifiers will default to the analog voltage level preset with the front panel float adjustment pots 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 40 40 A 80 Amps System Status and Alarm Reporting The PSCU will monitor system voltage using a high accuracy digital voltmeter attached to the system bus The PSCU will monitor system temperature using a temperature IC mounted in the PSCU The PSCU will monitor system current by summing the current reported by individual rectifiers The PSCU will report a number of system alarms including system high low voltage and high low temperature Refer to Section 4 6 for PSCU control functions MX28B400 24 VDC User s Manual Page 21 4 4 DC Distribution Distribution is included for up to 24 plug in circuit breakers These ci
43. nspect 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 M them for later use or dispose accordingly 3 2 Mechanical Installation Room Location NOTE The APC Model MX28B 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 local authority having jurisdiction Prior to installation drawings floor loading requirements external 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 Mounting This unit can be front or mid mounted on standard
44. nual Page 18 3 12 Full System Power Up To complete a full system power up perform the following steps 1 Turn OFF all the circuit breakers that supply ac power to the rectifiers in the MX28B power plant Turn on the external circuit breaker from the battery to the power plant Turn on all the circuit breakers that supply ac power to the rectifiers in the MX28B power plant Load circuit protection may now be enabled as required MX28B400 24 VDC Manual Page 19 4 Operation 4 1 Technical Description The MX28B 400 Power System is designed to supply safe 24 Vdc primary power through the use of up to four rectifier modules In conjunction with an external battery 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 1 A all the way to 100 A Battery recharging temperature compensation and low voltage disconnect are included The controller can monitor up to 4 discrete external events with dry contact inputs 4 2 Rectifier Management AC Input Power The basic component of the power system is the rectifier module which rectifies utility ac into nominal 24 Vdc Each rectifier module requires 176 264 Vac single phase 50 60 Hz A breaker installed in a remote panel should indi
45. ocols and command settings MX28B400 24 VDC User s Manual Page 42 6 Specifications The overall system specifications can vary depending upon the number of rectifier modules Note that some specification items are provided on a per rectifier basis and must be combined or totaled for a give system configuration 6 1 AC Input 1MRF28H27BV Rectifiers Nominal Input Voltage 230 Vac Input Voltage Range 176 264 Vac AC Frequency Range 47 63 2 Apparent Power Factor 99 Typical 98 Minimum Maximum Input Current per Rectifier 13 9 Amps 230Vac 1MRF28H27BV50 Rectifiers Nominal Input Voltage 277 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 277Vac MX28B400 24 VDC User s Manual Page 43 6 2 DC Output with either Rectifier Nominal Output Voltage factory set 27 2 Operating Voltage Range 22 29 Vdc Rated Output Current per Rectifier 100A Rated Output Power per Rectifier 2800 W 45 C Efficiency 91 Typical 6 3 Controls and Indicators Rectifiers Input Healthy LED AC power present Output Healthy LED DC output voltage within operating range 20 to 29 Vdc Output Current LED On when rectifier is supplying current Thermal Control LED On when one of thr
46. outputs Connectors J1 and J2 are located on the interface card mounted in the top left side of the unit Refer to the board layout in Figure 3 7 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 The following shows the alarm output connection designations RELAY OUTPUTS CONNT CONN2 9 9155 DCNS DIV 48V RIN Figure 3 7 1 Interface Board MX28B400 24 VDC Manual Page 15 RELAY TERMINAL OUTPUT DESIGNATION USER ALARM NOTES NO NC C J1 RELAY 1 NO1 NC1 C1 RELAY 2 NO2 NC2 C2 RELAY 3 NO3 NC3 C3 RELAY 4 NO4 NC4 C4 J2 RELAY 5 5 5 5 RELAY 6 NO6 NC6 C6 MINOR NO7 NC7 C7 MAJOR NO8 NC8 C8 Figure 3 7 2 Output Relay Connections 3 8 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 non alarm state Alarm Terminals OPEN NO C CLOSED NC C Figure 3 8 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 7 1 for Interface board connections Systems are shipped with jumper wires connecting each NC and corresponding C contact A jumper wire should be removed
47. pair or replacement of Product s or component s shall include all charges for replacement materials or repair labor Costs incurred for replacement 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 performe
48. r cover panel NOTE Circuit breaker alarm contacts close when the circuit breaker is tripped but not when it is turned OFF Figure 3 6 3 Installation of Circuit Breakers Load 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 will be lower and for constant power loads 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 MX28B400 24 VDC User s Manual Page 12 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 on 5 8 centers and are located directly above the corresponding circuit breaker The load returns connect to the return bus located just above and rearward of the breaker connection points as seen in Figure 3 6 4 The return bus provides 24 sets of threaded 10 32 holes on 5 8 centers and four sets of threaded 74 20 holes on 34 centers for connection of two hole lugs load return wires Load Connections should be made as shown in Figure 3 6 4 1 y QE OT e Figure 3 6 4 Standard lug
49. r daria 24 MX28B400 24 VDC User s Manual Page iv 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 cause serious personal injury or death catastrophic equipment WARNING indication of an electrical hazard that may damage or site destruction 1 2 General Precautions WARNING The power plant is supplied from a nominal 220Vac 50 60 Hz source Keep input enclosure cover in place when the system is operational or energized WARNING Hazardous energy levels are present on bare conductors in the 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 e Any jewelry rings or watches be removed while working on this equipment e 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 AN 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
50. r probe Circuit Breaker 1 Alias An alternate name alias that can be Cir Bkr 1 m4 Security Level 1 assigned to a circuit breaker if desired 24 MODULES CIRBKR ALIAS Circuit Breaker 24 Alias An alternate name alias that can be Security Level 1 assigned to a circuit breaker if desired MODULES CIRBKR ALIAS Circuit Breaker 1 Tripped An alarm that indicates Circuit Breaker 1 Security Level 1 is tripped MODULES CIRBKR SET ALM Circuit Breaker 24 Tripped An alarm that indicates Circuit Breaker Security Level 1 24 is tripped br Bie DW MODULES CIRBKR SET VUE a PR ALM ajor Compensation High Knee The temperature compensation high Comp Hknee m Security Level 1 knee is the point above which there is no 40 0 BATT COMP additional battery voltage compensation for further increases in temperature MX28B400 24 VDC User s Manual Page 26 Parameter Locations Descriptions and Default Values PARAMETER NAME DESCRIPTION DISPLAY SCREENS MENU LOCATION DEFAULT SETTINGS Compensation Low Knee The temperature compensation low knee Security Level 1 is the point below which there is no BATT COMP additional battery voltage compensation for further decreases in temperature Compensation Method One of three parameters that control the Security Level 1 dc output voltage Activate ON or de BATT COMP activate OFF battery temperature compensation
51. rcuit breakers can be 1 to 100 amps with 60 100 amp breakers requiring two positions and a circuit breaker adapter kit When a 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 NOTE Circuit breaker alarm contacts close when the circuit breaker is tripped but not when it is turned OFF 4 5 Battery Management Battery Charging and Protection Battery charging and protection are integrated into the 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 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 Batte
52. rd is only used to connect user inputs and output relays Interface board Fuse holder F1 F8 Lug connections labelled 48V and 48V RTN output connectors F1 F8 and connector J13 is not used 3 7 Monitoring and Relay Output Connections Front Panel DB9 Connection The front panel DB 9 connector is not used 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 SNMP card Smart Cable DB9 Connection The DB9 connector on the top right hand side of the unit uses the special RS 232 cable APC part number 940 0024C to allow local access through a Terminal Emulation program like HyperTerminal Procomm MX28B400 24 VDC User s Manual Page 14 RJ45 Ethernet Connector The optional management card 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 relay contacts The last two of these are preassigned as the Minor and Major relay outputs The Major relay is energized NO O 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
53. ry 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 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 MX28B400 24 VDC User s Manual Page 22 Battery Load Low Voltage Disconnect In order to prevent damage to the battery due to deep discharge the 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 to the rectifiers and the loads are disconnected from the system When the battery voltage reaches the threshold set by the LVD 1 Trip Voltage setting during discharge the power system will activate the LVD contactor to disconnect the battery or load from the system The LVD wil
54. s 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 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 Error Reference source not found 4 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
55. s holding a rectifier in the standby mode Rectifier Standby Alarm Status The status will be ON if the control unit Rect 1 Stdby Status Only is holding the rectifier in the standby OFF MODULES RECT INFO mode NOTE This information can be viewed for each rectifier installed by using the horizontal arrow keys Store Configuration Setting this parameter to Enable will Store Cfg Security Level 1 cause the current rectifier configuration Disable SYSTEM DIAG to be stored the display toggles back to Disable after entry System Current The total system output current Sys Current Status Only calculated as the sum of the individual 145 8 STATUS rectifier output currents System High Temperature The output relay energized if the System Sys HT Alm m4 Alarm Temperature exceeds the system high Minor Security Level 1 temperature threshold SYSTEM SET ALM System High Temperature System Temperature is ambient Sys HT Thr m Threshold temperature measured inside the 70 0 Security Level 1 controller An alarm will be reported if SYSTEM SET ALM temperature is higher than the temperature entered System High Voltage alarm The output relay energized if the System Sys HV Alm m4 Security Level 1 Voltage is above the System High Minor SYSTEM SET ALM Voltage threshold System High Voltage System Voltage is bus voltage measured Sys HV Thr m Threshold by the controller An alarm will be 29 00 V Security Level 1 reported i
56. sc Alm Batt HV Thr Batt Alm e e Batt LV Thr Batt LV Alm Batt Thr Batt Alm Batt LT Thr Batt LT Alm BAT Batt Float Batt Rech BAT Comp Method e e Comp Comp LKnee MX28B400 24 VDC User s Manual Page 39 Level Third Level Fourth Level MX28B400 24V T PIN OEM PIN MX28B400 24V N OEM OEM R Offset OEM R Gain OEM Offset Gain 5 Offset 5 Gain Front Panel LED Indicators Major Red On when Major Relay is de energized Minor Yellow On when Minor Relay is energized Normal Green On when no alarms are active ALM 1 Red On when Output Relay 1 is energized ALM 2 Red On when Output Relay 2 is energized ALM 3 Red On when Output Relay 3 is energized ALM 4 Red On when Output Relay 4 is energized ALM 5 Red On when Output Relay 5 is energized ALM 6 Red On when Output Relay 6 is energized 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 MX28B400 24 VDC User s Manual Page 40 4 7 Alarm Outputs Output Relay
57. shown Display of up to 16 active alarms a typical alarm screen is shown Battery current measured by the system controller at the battery current shunt The output relay energized if the battery discharge current exceeds the programmed battery discharge threshold An alarm is generated if the battery discharge current exceeds this value One of three parameters that control the output voltage Set the Float Voltage at 25 C battery temperature per the battery manufacturers recommendations The output relay energized if the battery temperature exceeds the Battery High Temperature threshold Battery Temperature is temperature measured at the battery probe An alarm is generated if the battery temperature exceeds this value The output relay energized if the dc output voltage rises above the battery high voltage threshold Battery High Voltage Threshold An alarm will be reported if temperature Security Level 1 BATT SET ALM is lower than the temperature entered An alarm is generated if the dc output voltage rises above this value MX28B400 24 VDC User s Manual DISPLAY SCREENS DEFAULT SETTINGS Address 1 m APC DCNS Inc Address 2 m 11035 Switzer Av Address 3 n Dallas X Alarm Item 1 4 Batt LV Alm Onm Item 16 4 No Alarms Ba Alarm Current 15 0 A Batt Disc Alm m t Minor Batt Disc Thr m 10 A Batt HT
58. te Headquarters Connect 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 Fore mail addresses and local country specific customer support telephone numbers worldwide refer to http www apc com support contact For e mail addresses and technical support telephone number of major APC regional customer support centers use the following list APC Headquarters 1 800 800 4272 US and Canada 1 800 800 4APC Latin America 1 401 789 5735 US apctchla apcc com Europe Middle East 353 91 702020 Ireland Africa apceurtech apcc com Japan 03 5434 2021 jsupport apcc com 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 MX28B400 24 VDC User s Manual Page 47 6 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 the ordinary course of Buyer s business APC PRODUCTS COVERED Product or Products Magnum MX28B400 24 Terms of Warranty APC warrants that the Product shall b
59. tle Levelj Third Level Fourth Level MX28B400 24V STATUS ALARMS Sys Voltage Sys Current Conv Voltage 9 Conv Current Sys Temp Batt Current Batt Temp MX28B400 24V US ALARMS SYSTEM Alarm Item 1 Alarm Item 2 Alarm Item 3 Alarm Item 14 Alarm Item 15 Alarm Item 16 MX28B400 24V SYS MS SYSTEM MODULE SET ALM SETUP DA Sys HV Thr Sys HV Alm Sys LV Thr Sys LV Alm HV Thr Conv HV Alm Conv LV Thr Conv LV Alm Rect Cfg Alm Rect lofN Alm Rect 20fN Alm MX28B400 24 VDC User s Manual Page 34 Level Second Level Third Level Fourth Level Conv Cfg Alm Conv lofN Alm Conv 20fN Alm Sys HT Thr Sys HT Alm Sys LT Thr Sys LT Alm Hw Sys V Alm Hw Cnv V Alm Hw Batt C Alm Hw Batt T Alm Hw Sys T Alm Hw LVD1 Alm Hw LVD2 Alm SYS F LM SETUP DATE PIN 1 PIN 2 Address 1 Address 2 Address 3 Model Fahrenheit Cntrl Rev FW Version Display Type SYS LY DATE OUT RLY Date
60. vidually 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 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 The PSCU can trigger output relays in the event of a rectifier alarm Refer to Section 4 6 for PSCU control functions MX28B400 24 VDC Manual Page 20 4 3 System Management System Output Capacity The MX28B 400 supplies a maximum of 400 amps or 300 amps with N 1 redundancy The housing for this configuration provides space for two rectifier shelves that can hold up to four rectifiers each a control unit and one tier of up to 24 distribution circuit breakers System Voltage Control The PSCU monitors and adjusts the system voltage It uses a voltage trim input to the rectifier to precisely control the 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 fai

American Power Conversion MX28B400 User's Manual

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