Instruction/ maintenance manual of the product MX28B2400 American Power Conversion
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MX28B1200/2400 MX28B1200/4800 -48 VDC POWER SYSTEMS User’s Manual (Document # 990-1 148A).
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page ii Table of Contents 1 SAFETY FIRST! .................................................................................................................. ...1 1.1. W ARNING S YMBOLS .........
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page iii 3.10. E XTERNAL A LARM I NPUT C ONNECTIONS .......................................................................... 25 3.11. R ECTIFIER M ODULE I NSTALLATION .........................
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page iv 6.3. C OMMAND AND M ONITORING P ROTOCOL .........................................................................54 7 PREVENTIVE MA INTENA NCE............................................
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page v Revision History Revision Date By Description 1 31 JAN, 2002 JNF Converted to APC numbering 2 28 SEP, 2003 BET Updated Format and added 4800 Table of Figures FIGURE 2.2-1 MX28B-1200 –48 VDC PO WER PLANT RECTIFIER BAY.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 1 1 Safety First! It is very important to follow all safety procedures when unpacki ng, installing and operating any sort of power equipment.
2 Introduction 2.1. General Information DC Power Plants from APC have unique features that make them easy to in stall, maintain, and upgrade. The rectifier units are modular and tr uly “hot-pluggable” into the shelf assembly without any separate AC wiring.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 3 Figure 2.2-1 MX28B-1200 –48 VDC Power Plant Rectifier Bay.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 4 Figure 2.2-2 MX28B Block Diagram.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 5 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 6 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).
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 7 Figure 3.2-2 MX28B-1200-2400 has a maximum capacity of 2400 Amps. Figure 3.2-3 The MX28B1200-4800 can be expanded to 4800 Amps.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 8 Circuit Breaker/LVD Ri bbon Cable Connections Additional cables must be conne cted between cabinets to ensure that the circuit breaker alarms in the expansion bays are repor ted correctly.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 9 Fuse Alarm Ribbon Cable Connections There is a 16-conductor ribbon cable, if any bay has fu ses 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 10 input. The AC wiring, from the AC input terminal block connections to the hot-pluggable AC input connector for each rectif ier, is factory installed.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 11 If the AC input power is prov ided from a three-phase distribut ion 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 12 Connecting the Battery Cables WARNING : Make certain that the battery polarity is correct when making connections to the Model MX28B DC po wer plant. Incorrect connection could cause severe equipment damage.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 13 Battery Temperature Probe Installation The optional temperature probe is used to monitor the battery string temperature. To get the most representative temperatur e measurement, the probe should be placed in contact with a battery cell that is centrally loca ted.
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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 15 the Wago connectors based on what bay the circuit br eaker 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 16 10 A FFA-0017 70 A 530-9089 15 A 530-9093 80 A 530-9090 20 A FFA-0018 100 A 530-9091 30 A FFA-0019 Figure 3.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 17 DC Bolt-in Circuit Breakers Bolt in Breakers in a variety of sizes up to 700 Amps are avai lable. Triple pole breakers are available in sizes ranging from 400-700 Amps. Double pole brea kers are available in sizes ranging from 250-400 Amps.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 18 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: Fuse 13-16.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 19 3.7. Installat ion 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 20 Bolt-in Circuit Breaker Installation 1) Remove the circuit breaker cover panel and the pl astic cover(s) from the desired location(s). 2) Install the circuit breaker(s) by bolting the ci rcuit breaker onto the bus at the bottom of the assembly.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 21 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 t he fuses(s) into the fuse holder.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 22 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 requirement s.
Figure 3.8-1 Load connections for snap-in breakers Figure 3.8-2 Return Connections GMT Fuse Connections GMT fuses are only connected to -48VDC if the system has been purchased with the GMT fuse option.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 24 The DB9 connector on the top right hand side of the unit, behind a blank pa nel directly above the controller, uses the s pecial RS-232 cable (APC part number 940-0024C) to allow local access through a Terminal Emulation progr am like HyperTerminal™ or Procomm™ .
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 25 RELAY OUTPUT TERMINAL DESIGNATION NO-NC-C USER ALARM NOTES RELAY #1 RELAY #2 RELAY #3 RELAY #4 RELAY #5 RELAY #6 MINOR MAJOR NO1-NC1-C1.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 26 3.11. Rectifier Module Installation WARNING : Rectifier DC output circuits would be damaged if battery were installed incorrectly.
4 Commissioning and Preventive Maintenance 4.1. Pre-Commissioning Inspection Environment 1. Ensure the DC system environment is suitable for operation. 2. Ensure that there is sufficient clearance around the system for service. 3. Ensure that there is no sign of damage to the DC system.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 28 b. Case leaks . c. Post- seal leaks. d. Pressure relief valve leaks (VRLA only). e. Case swelling (VRLA only). f. Case swelling (VRLA only). 10. Check the torque of all battery inter- cell connector in accordance with the battery manufacturer’s specifications.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 29 DC Power Up: 1. 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 offs et setting under the OEM menu. If the R Offset setting is more than +/- 1.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 30 Circuit Breaker/ Fuse Test: 1. For plug- in circuit breakers. Monitor al arm screen for circuit break er alarm while shorting out each pair of alarm contacts (using a pair of tweezers) on the circ uit breaker interface circuit board.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 31 4.3. Final Inspection: 1. Verify that the interi or and exterior of the syste m is clean and free from debris.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 32 5 Operation 5.1. Technical Description The MX28B-1200/2400 Powe r System is designed to supp ly s afe –54 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 33 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 34 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 tem perature IC mounted in the PSCU.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 35 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 25ºC. As temperature rises, electrochemical activity in a battery increases.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 36 right corner of the display. If a security level higher than the one presently set is required to modify the parameter, "s+" is displayed instead of “m+”.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 37 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 positi on the cycling cursor below “IN-RLY”.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 38 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Battery High Temperature Alarm Security Level {1} [BATT/SET-ALM] The output relay energized if the battery temperature exceeds the Battery High Temperature threshold.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 39 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Circuit Breaker 1 Tripped Security Level {1} [MODULES/CI.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 40 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS FUSE 1 Blown Security Level {1} [MODULES/FUSE/SET-ALM] • • • FUSE 8 Blown Security Level {1} [MODULES/FUSE/SET-ALM] The Output Relay that is energized whe n FUSE Fuse 1 is blown.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 41 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS LVD 1 or 2 Option Security Level {1} [MODULES/LVD/SET-ALM] Must be set to “Enable” if the unit has an LVD.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 42 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Output Relay 1 Delay Security Level {1} [SYSTEM/OUT-RLY/.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 43 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Rectifier De scription {Status Only} [MODULES/RECT/INFO] Displays the model number of the installed rectifier.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 44 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS System High Voltage alarm Security Level {1} [SYSTEM/SET-ALM] The output relay energized if the System Voltage is above the System High Voltage threshold.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 45 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION DISPLAY SCREENS / DEFAULT SETTINGS Time Security Level {1} [SYSTEM/DATE] Internal system clock time (24-hour format). Used as a date stamp in the event log.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 46 Control Unit Menu Structure The complete menu structure sho wn in the order in which it is acces sed from the control unit display is presented in out line form below. Each indentation to th e right represents a m enu level b elow the indicated title.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 47 Top Level S e c o n d L e v e l T h i r d L evel Fourth Level • • Hw Batt C Alm • • Hw Batt T Alm • • Hw Sys T Alm • • .
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 48 Top Level S e c o n d L e v e l T h i r d L evel Fourth Level • • • Out-Rly 3 • • • Out-Rly 4 • • • Out-Rly 5 • •.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 49 Top Level S e c o n d L e v e l T h i r d L evel Fourth Level • • • Rect Fail Comm • • MOD:REC: + AM INFO Rect # Desc • •.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 50 Top Level S e c o n d L e v e l T h i r d L evel Fourth Level • • • FUSE 6 Alm • • • FUSE 7 Alm • • • FUSE 8 Alm • .
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 51 Top Level S e c o n d L e v e l T h i r d L evel Fourth Level • • MOD:LVD: + LM PARAM LVD 1 Trip • • • LVD 1 Reset • • .
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 52 Front Panel LED Indicators Major (Red) On when Major Relay is de-energized* Minor (Yellow) On when Minor Relay is energized Normal (Gre.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 53 5.8. External Alarm Inputs (Input Relays) The controller can monitor any exte rnal device that uses a swit ch or relay to output status information. Connecting the external device to the input relay connections is the first step.
6 Remote Monitoring 6.1. Description Remote monitoring and control of the DC power system is acco mplished through the use of the optional APC Network Manage ment card. This c ard is a s eparate module mounted into the top panel of the system controller module.
7 Preventive Maintenance Preventive Maintenance is typically performed on a quarterly basis. 7.1. Equipment 1. 4 Digit Voltmeter. 2. Clamp-on Ampere meter. 3. Standard Insulated tools. 7.2. Inspection Environmental Inspection 1. Ensure the DC system environment is suitable for operation.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 56 a) DC Voltage Rating. b) DC Current Rating c) Interrupting Current Rating Battery Visual and Safety Inspection 1. Check that the battery temperature probe is firmly attached to the battery.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 57 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.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 58 Battery Temperature Test If the battery teperature probe is used in this syst em, verify that the battery temperature i s correct. LVD Test 1. Verify that the Battery Float voltage is set to negative (-) 54.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 59 9. Ensure that all protective covers are repl aced and that the battery is electrically non- hazardous to personnel that c ould be working in the vicinity. Detail any discrepancies. 10. Download the Cellcorder to a PC and create a data file for each battery string.
8 Specifications The overall system specifications can vary, depending upon the number of rectifier modules. Note that some specification items are provided on a “per rectif ier” basis and must be combined or totaled for a give system configuration.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 61 8.2. DC Output (with either 1MRF28H54BV Rectifiers and 1MRF28H54BV50 Rectifiers) Nominal Output Voltage (f actory set) 54.5 VDC Operating Voltage Range 44 – 58 VDC Rated Output Current (per Rectifier) 50 A Rated Output Power (per Rectifier) 2800 W (45ºC) Efficiency 91% Typical 8.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 62 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 (54.5 VDC). Boost/Equalize Trim Pot The boost/equalize pot is used to adjust the default boost equalize voltage (57.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 63 8.4. Mechanical Dimensions 84” high x 26” wide x 26” deep Housing 400-600 lbs. (181-272 Kg) Weight Rectifier (each) 11 lbs (5Kg) Color Dawn Gray Mounting Floor Mounting 8.
MX28B1200/2400 MX28B1200/4800 –48 V DC User’s Manual Page 64 9 APC W orldwide Customer Support Customer Support for this or any other APC product is available at no charge.
10 Limited Pr oduct W arranty The limited warranty pro vided by American Power Co nversion Corporation ("APC") in this Statement of Limited Factory Warranty applies only to Produc ts Buyer purchases for your commerc ial or industrial use in the ordinary course of Buyer's business.
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