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APC VS 100 manual

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Table of contents for the manual

  • Page 1

    Magnum VS 50 Magnum VS 100 -48 Vdc Power Systems User’s Manual[...]

  • Page 2

    Magnum VS –48 Vdc User’s Manual Page ii Table of Contents 1 Safety First!.................................................................................................................. ...........1 1.1. W ARNING S YMBOLS .........................................................................................................1 1.2. G ENERAL P[...]

  • Page 3

    Magnum VS –48 Vdc User’s Manual Page iii AC Powe r Up .................................................................................................................... ....17 DC Power Up: ................................................................................................................... ....17 Rectifier Test:.................[...]

  • Page 4

    Magnum VS –48 Vdc User’s Manual Page iv 6.5. C ONTROLLER WITHOUT D ISPLAY ...................................................................................... 36 6.6. O PERATION U SIN G THE RS-232 C OMM P ORT ..................................................................36 6.7. O PERATION U SIN G THE 10/100 B ASE T E THERNET P ORT .......[...]

  • Page 5

    Magnum VS –48 Vdc User’s Manual Page v Revision History Document # & Rev Date By Description 990-1479 06 MAY, 2003 BET Initial Release 990-1479A 03 JUL, 2003 BET Clean-up after Pilot Run 990-1479B 30 SEP, 2003 BET Add Controller with Display 990-1479C 28 OCT, 2003 BET Correct dc connections 990-1479D 06 JAN, 2004 BET Added Output Relays 2-6[...]

  • Page 6

    Magnum VS –48 Vdc User’s Manual Page 1 1 Safety First! It is very important to follow all safety proc edures when unpacking, installing and operating any sort of power equipment. 1.1. Warning Symbols CAUTION : An indication that special care is required to prevent injury, equipment damage or misuse. WARNING : An indication of an electrical haza[...]

  • Page 7

    Magnum VS –48 Vdc User’s Manual Page 2 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. The Magnum VS 50 has 1 shelf, holding up to fi[...]

  • Page 8

    Magnum VS –48 Vdc User’s Manual Page 3 AC DC Contro l AC DC Contro l AC DC Contro l AC DC Contro l AC DC Contro l GND L1 L2/N GND L1 L2/N GND L1 L2/N GND TRM15 1 2 3 4 5 6 7 8 ALM RTN ALM RTN ALM RTN ALM RTN 1 2 3 4 5 6 7 8 9 1 2 3 4 MAJ NC MAJ NO MIN NC MIN NO USER NC USER C MIN C MAJ C USER NO TMP -BAT +12 PWR -PWR +PWR CONTROL BUS Power Dist[...]

  • Page 9

    Magnum VS –48 Vdc User’s Manual Page 4 3 Installation 3.1. Unpacking Equipment Remove equipment from packing material and inspect for shipping damage or missing items. It is important to report damage or material shortages to the shipping carrier while a representative is on site. If concealed damage or material shortages are found at a later t[...]

  • Page 10

    Magnum VS –48 Vdc User’s Manual Page 5 Ventilation The rectifier modules for this system have fans t hat provide front-to-rear airflow for internal cooling. The power system housing should be moun ted such that there is free airflow to the front and back of the unit. [Refer to Section 9.5 for environmental characteristics.] Free airflow should [...]

  • Page 11

    Magnum VS –48 Vdc User’s Manual Page 6 Rectifier Terminal # Function Terminal # Function Terminal # Function Rectifier 1 TRM2 Ground TRM5 Line or Neutral TRM8 Line Rectifier 2 & 3 TRM3 Ground TRM6 Line or Neutral TRM9 Line Rectifier 4 & 5 TRM4 Ground TRM7 Line or Neutral TRM10 Line Chassis TRM1 Ground Figure 3.3-3 AC Input Wiring AC Pow[...]

  • Page 12

    Magnum VS –48 Vdc User’s Manual Page 7 3.4. Battery Connections WARNING : Hazardous energy levels are present on bare conductors in the dc distribution connecti on area of the plant. Accidental shorting of distribution conductors can cause arci ng and high currents that can cause serious burns or other physical harm. It is recommended that: •[...]

  • Page 13

    Magnum VS –48 Vdc User’s Manual Page 8 Figure 3.4-1 Battery Cable Connection Locatio ns Battery Temperature Probe Installation The temperature probe is used to monitor the battery string temperature. To get the most representative temperature meas urement, the probe should be placed in contact with a battery cell that is centrally loca ted. The[...]

  • Page 14

    Magnum VS –48 Vdc User’s Manual Page 9 3.5. Counter Electro-Motive Force (CEMF) Cell Connections WARNING : Hazardous energy levels are present on the CEMF connection area of the plant. Accidental shorti ng of conductors can cause arcing and high currents that can cause seriou s burns or other physical harm. In some applications, a CEMF cell is [...]

  • Page 15

    Magnum VS –48 Vdc User’s Manual Page 10 3.7. Load Protection Installation Circuit Breaker Installation Standard circuit breaker output boards are avai lable with two 30-A breakers or one 60-A breaker. Output boards are instal led at the factory and are generally not field replaceable units. Contact APC if the output configur ation is not suitab[...]

  • Page 16

    Magnum VS –48 Vdc User’s Manual Page 11 3.8. Load Connections Cable Size Considerations The dc load cable(s) should be sized to limit the voltage drop from the 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 t he voltage will be lo[...]

  • Page 17

    Magnum VS –48 Vdc User’s Manual Page 12 Figure 3.8-2 Top Shelf GMT Fuse Connections Figure 3.8-3 Bottom Shelf GMT Fuse Connection s 3.9. Monitoring and Relay Output Connections Front Panel DB9 Connection The front panel DB-9 connector is used to hook up a standard RS-232 cable (such as APC part number 0129-XX. A 0129-6 is incl uded with this ma[...]

  • Page 18

    Magnum VS –48 Vdc User’s Manual Page 13 Figure 3.9-3 shows the alarm output connecti on designations. Whenever possible use the common and normally closed contacts. If the alarm wiring gets pulled loose, or the controller is removed, you will get an alarm. The Major re lay is energized (C-NO contacts closed) during normal (non-alarm) operating [...]

  • Page 19

    Magnum VS –48 Vdc User’s Manual Page 14 OUT RELAY #6 N/A NO N/A MINOR C N/A NC N/A NO N/A MAJOR C N/A NC N/A Figure 3.9-3 Output Relay Connections External Alarm Input Connections Four external alarm inputs with assignable relay outputs are available. User 1 and 2 inputs respond only to external dry contact closur es between normally open (NO) [...]

  • Page 20

    Magnum VS –48 Vdc User’s Manual Page 15 2) Slide the rectifier module into the shel f between the guides until it is fully seated. 3) Fasten the rectifier in place with t he captive rectifier retaining screws. Since all adjustments are m ade from the system controller, no rectifier adjustments are necessary. 3.11. Controller Module Installation[...]

  • Page 21

    Magnum VS –48 Vdc User’s Manual Page 16 4 Commissioning This section is intended as a guide when powering up a system for the first time. It may not be desirable to perform some steps depending on t he particular installation. Refer to the appropriate section for information relating to how these steps should be performed. 4.1. Pre-Commissionin[...]

  • Page 22

    Magnum VS –48 Vdc User’s Manual Page 17 8. Check that anti-oxidation compound is properly applied. 9. Visually inspect each cell for: a. Cracks. b. Case leaks . c. Post-seal leaks. d. Pressure relief valve leaks (VRLA only). e. Case swelling (VRLA only). 10. Check the torque of all battery inter- cell connector in accordance with the battery ma[...]

  • Page 23

    Magnum VS –48 Vdc User’s Manual Page 18 Rectifier Test: 1. To verify that all rectifiers are reporting correctly to the controlle r, navigate through the menu and verify that the status for ever y rectifier in the system is correct. 2. Remove any rectifier and ve rify that you get a Minor Rela y Output for rectifier 1 of n failure. 3. Remove a [...]

  • Page 24

    Magnum VS –48 Vdc User’s Manual Page 19 Output Relay 1: 1. Minor and Major output relays were te sted in the rectifi er test section. 2. Change the alarm to desired relay output via the controller for any relay output that will be used. All alarm parameters are shipped as ei ther major or minor, but may be changed to output relay 1. 3. Program [...]

  • Page 25

    Magnum VS –48 Vdc User’s Manual Page 20 5 T echnical Description The Power System is designed to supply safe –54 Vdc primary power th rough the use of up to 10 rectifier modules. The controll er will monitor all functions and provides battery management including controlled battery recharge with temperature compensat ion and low voltage disco[...]

  • Page 26

    Magnum VS –48 Vdc User’s Manual Page 21 System Current Monitor The controller monitors individual rectifier cu rrents 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 = L[...]

  • Page 27

    Magnum VS –48 Vdc User’s Manual Page 22 GMT Fuses When a GMT fuse trips, a fuse element burns out allowing the indicator to connect dc power to the alarm contact. This turns on the fuse alarm LED on the fuse panel indicating the affected group and the controller repor ts a fuse alarm. Each controller fuse alarm combines alarms from 4 individual[...]

  • Page 28

    Magnum VS –48 Vdc User’s Manual Page 23 Battery Equalization Battery equalization equalizes the spec ific gravity of the el ectrolyte in the cells of a battery. It is accomplished by applying a controlled overc harge to the battery. Equalization may be appropriate (1) after a battery has been in float charge for ext ended periods time, (2) afte[...]

  • Page 29

    Magnum VS –48 Vdc User’s Manual Page 24 Battery Low Voltage Disconnect In order to prevent damage to the battery due to deep discharge, the dc power syst em has hardware and software support for a battery Low Voltage Disconnect (LVD). When the battery voltage reaches the threshold set by the LVD 1 Trip Voltage setting during discharge, the dc p[...]

  • Page 30

    Magnum VS –48 Vdc User’s Manual Page 25 5.5. Controls and Indicators Controller with Display The Magnum VS may be equipped with an optional adv anced controller. This controller has an LCD display and a 5-button keypad. This controller uses the normal control card slot as well as the adjacent slot for rectifie r 5. Most common parameter monitor[...]

  • Page 31

    Magnum VS –48 Vdc User’s Manual Page 26 network management card. This can be used to give specific information on the exact nature of the active alarm. 5.7. External Alarm Inputs (User Input) The controller can monitor any external device t hat uses a voltage free (“d ry contact”) switch or relay to output status information. The four ex te[...]

  • Page 32

    Magnum VS –48 Vdc User’s Manual Page 27 6 Operation 6.1. Description The Magnum VS is designed for years of operation wit h no user input. The power system is pre-programmed at the factory with all parameters needed for normal operation. The front panel LEDs and the alarm output rela ys, indicate the general health of the unit. There are 2 cont[...]

  • Page 33

    Magnum VS –48 Vdc User’s Manual Page 28 J1 1 1 1 10 1 65 J5 J3 J13 J9 J8 J2 J12 J4 DB9 - RS232 Port MAJOR DC GOOD MINOR OUT RLY VR1 J10 J11 System Voltage Select SNMP Interface Vtrim Dropout Parameter Change Lockout Firmware Change Positive Test Jack Negative Test Jack Display Contrast "HEARTBEA T" LED Display Interface Display Backli[...]

  • Page 34

    Magnum VS –48 Vdc User’s Manual Page 29 If the keypad is not pressed for approximately 2 minutes the display will revert to the Status display and the backlight will extinguish. It will al so clear any PIN that may have been entered. Pressing any key during this mode will cause the display of the Main Menu and permit navigation among the menus.[...]

  • Page 35

    Magnum VS –48 Vdc User’s Manual Page 30 Figure 6.4-1 Parameter Locations, Descriptions, and De fault Values PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default Settings in BOLD) Alarms Item 1 {Status Only} [ALARMS] [ 告警] Display of up to 16 active alarms. Scroll up or down to select individual alarms. Alarm Status Only Battery Cap[...]

  • Page 36

    Magnum VS –48 Vdc User’s Manual Page 31 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default Settings in BOLD) Battery Temperature [STATUS/BATTERY/ PARAMETERS] [ 状态 / 电池 /参数] Battery temperature measured by the system controller at the optional battery temperature sensor probe. Battery Temperature Status Only Date Setup [SE[...]

  • Page 37

    Magnum VS –48 Vdc User’s Manual Page 32 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default Settings in BOLD) Equalization Duration [SETUP/BATTERY/ VOLTAGE/EQUALIZATION/ DURATION] [ 设置 / 电池 / 电压 / 均充 / 均充时间 ] This setting defines the number of ho urs the batteries will be equalized in all methods of equalizatio[...]

  • Page 38

    Magnum VS –48 Vdc User’s Manual Page 33 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default Settings in BOLD) Rectifier Current Output Status {Status Only} [STATUS/RECT] [ 状态 / 模块] A display of the dc output current for the individual rectifier. Scroll up or down to select individual rectifiers. Rectifier Current Output Status[...]

  • Page 39

    Magnum VS –48 Vdc User’s Manual Page 34 Figure 6.4-2 Magnum VS English Display Tree  ENGLISH  SETUP  STATUS  ALARMS ENTER PIN 2 2 2 2   SYSTEM  BATTERY  RECTIFIER  SYSTEM  BATTERY  SET PIN  PARAMETERS  TIME/DATE  PARAMETERS  MODE  TEST  TIME/DATE  FLOAT  EQUALIZATION  VOLTAGE  CAP ?[...]

  • Page 40

    Magnum VS –48 Vdc User’s Manual Page 35 Figure 6.4-3 Magnum VS Chinese Display Tree  设置  状态  告警 PIN 码输入 2 2 2 2   系统  电池  模块  系统  电池  PIN 码设置  参数  时/日  参数  模式  测试  时/日  浮充  均充  电压  容量  电流  测[...]

  • Page 41

    Magnum VS –48 Vdc User’s Manual Page 36 6.5. Controller without Display This controller does not have a built in display and ke ypad. It does not use the fifth rectifier slot. All parameter changes or vi ewing of status is made either lo cally using a PC or remotely by interface to the network management card. Refe r to Figure 6.5-1 for the fro[...]

  • Page 42

    Magnum VS –48 Vdc User’s Manual Page 37 6.7. Operation Using the 10/100 BaseT Ethernet Port The RJ-45 10/100 Base-T port is primarily intended for connecti on to an intranet for remote access to the DC power system. However with the us e of a crossover cable or a hub, a direct PC to 10/100 Base-T local connection may also be made. After the Man[...]

  • Page 43

    Magnum VS –48 Vdc User’s Manual Page 38 Figure 6.8-1 Parameter Locations, Descriptions, and Setting s PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Alarms Item 1 {Status Only} [System/ Active Alarms] • • • Alarms Item 16 [System/ Active Alarms] Display of up to 16 active alarms (a typical alarm screen is [...]

  • Page 44

    Magnum VS –48 Vdc User’s Manual Page 39 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Battery Max Recharge {Status Only} [System/ DC Parameters] This is just a convenient place to view the Battery Max Recharge Current parameter. Go to Batteries/Parameters to change setting. Status Only Battery Maximum Recharge [...]

  • Page 45

    Magnum VS –48 Vdc User’s Manual Page 40 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Current Limit Alarm Status {Status Only} [Power Modules/Rectifiers] The status will be “ON” if the rectifier ha s been forced into its current limited mode. Status Only Date [System/ Date & Time] Internal network manag[...]

  • Page 46

    Magnum VS –48 Vdc User’s Manual Page 41 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Hardware System Voltage Alarm [Power Modules/Rectifiers] Defines the output relay that is energized if there is a hardware failure in the system voltage monitoring function. Ignore, Minor , Major Output Relay 1-6 Hardware Temp[...]

  • Page 47

    Magnum VS –48 Vdc User’s Manual Page 42 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Low Temperature Th reshold [System/ DC Parameters] System Temperature is ambient temperature measured inside the controller. An alarm will be reported if temperature is lower than the temperature entered. Not the same as batte[...]

  • Page 48

    Magnum VS –48 Vdc User’s Manual Page 43 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Output Relay 1 Alias [System/ Out-Rly/Alias] • • • Output Relay 6 Alias [System/ Out-Rly/Alias] An alternate name (alias) can be assigned to Output Relay 1 if desired. • • An alternate name (alias) can be assigned to[...]

  • Page 49

    Magnum VS –48 Vdc User’s Manual Page 44 PARAMETER NAME/ [MENU LOCATION] DESCRIPTION SETTINGS (Default settings in BOLD) Rectifier Fault Alarm (RFA) Status {Status Only} [Power Modules/Rectifiers] The status will be on if the rectifier output has failed. Status Only Rectifier RFA Alarm [Power Modules/Rectifiers] Defines the output relay that is [...]

  • Page 50

    Magnum VS –48 Vdc User’s Manual Page 45 the system and the bus voltage reac hes the level defined by the LVD 1 Reset Voltage variable. The LVD control can be disabled on the LV D parameters screen in the controller. The LVD will not be energized until a battery string is installed with the correct polarity and the battery disconnect switch is t[...]

  • Page 51

    Magnum VS –48 Vdc User’s Manual Page 46 information on the exact nature of the active ala rm. Using the example above, if you use the default programming the message “A minor relay in the power plant has been activated.” Using the relay mapping and al iasing you could get the additiona l message “An output relay (1, Batt Discharge) for th[...]

  • Page 52

    Magnum VS –48 Vdc User’s Manual Page 47 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 environm ent is suitable for operation. 2. Ensure that t[...]

  • Page 53

    Magnum VS –48 Vdc User’s Manual Page 48 c) Interrupting Current Rating Battery Visual and Safety Inspection 1. Check that the battery temperature probe is firmly attached to the battery. 2. Check the mechanical integrity of the batte ry framing, racking, or cabinet. Tighten where necessary. 3. If there is a battery disconnect device fitt ed, en[...]

  • Page 54

    Magnum VS –48 Vdc User’s Manual Page 49 3. Remove the second rectifier and verify that you get a Major alarm fo r Rect 2 of n failure on the controller and the customer remote alarm panel. 4. After the fan has completely stopped spinning, insert a plas tic pen or plastic screwdriver into the fan blade of one of the rectifiers and reinsert both [...]

  • Page 55

    Magnum VS –48 Vdc User’s Manual Page 50 Battery Preventive Maintenance Procedure The purpose of the preventive maintenance is to ensure that the battery is in good, working condition. The observations, measurements, and tests performed are des igned to determine the “state of health” of the battery. It will also allow for the prediction of [...]

  • Page 56

    Magnum VS –48 Vdc User’s Manual Page 51 8 Alarm Summary ALARM/ [MENU LOCATION] DESCRIPTION DEFAULT SETTINGS Battery Discharge Alarm [Batteries/Parameters] The battery discharge current exceeds the programmed battery discharge threshold. Minor Battery High Temp Alm [Batteries/Parameters] The battery temperature exceeds the Battery High Temperatu[...]

  • Page 57

    Magnum VS –48 Vdc User’s Manual Page 52 ALARM/ [MENU LOCATION] DESCRIPTION DEFAULT SETTINGS System LT Alm [System/ DC Parameters] The System Temperature is below the System Low Temperature threshold. Not the same as battery temperature alarm. Minor Low Voltage Alarm [Power Modules/Rectifiers] The System Voltage is below the System Low Voltage t[...]

  • Page 58

    Magnum VS –48 Vdc User’s Manual Page 53 9 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 given system configuration. 9.1. AC Input TWF0500H54B Rectifier Input Voltage R[...]

  • Page 59

    Magnum VS –48 Vdc User’s Manual Page 54 Magnum VS 100 Power System Input Voltage Range 85 – 264 Vac AC Frequency Range 47 – 63 Hz Apparent Power Factor 99% Typical, 98% Minimum Input Current 55 A @ 115 Vac 37 A @ 230 Vac 9.2. DC Output TWF0500H54B Rectifier Output Voltage (factory set) 54.5 Vdc Operating Voltage Range 44 – 58 Vdc Efficien[...]

  • Page 60

    Magnum VS –48 Vdc User’s Manual Page 55 Magnum VS 50 Power System Output Voltage (factory programmed) 54.0 Vdc Operating Voltage Range 47 – 56.5 Vdc Rated Output Current 50 A Efficiency 85% Typical Over Voltage Protection 59.5 Vdc Output Current 45 A Minimum Continuous at 115 Vac Input 52.5 A Minimum Continuous at 230 Vac Input. Current Limit[...]

  • Page 61

    Magnum VS –48 Vdc User’s Manual Page 56 9.3. Controls and Indicators TWF0500H54B Rectifier Input Healthy LED AC power present. Output Healthy LED DC output vo ltage between 39.5 to 59.5 Vdc. Current Limit LED On when rectifier is in current limit. Overvolts LED On when rectifier is abov e 57 Vdc. (Must be powered down to reset) Magnum VS Contro[...]

  • Page 62

    Magnum VS –48 Vdc User’s Manual Page 57 Dimensions 5-1/4 in (13.3 cm ) high x 17-1/4 in (43.8 cm) wide x 13 in (33cm) deep Weight 15 lb. (6.8 kg) Color Black Front, Yellow zinc sides and back Mounting 19” Rack Mounting (23” Optional) Magnum VS 100 Power System Dimensions 10-1/2 in (26.6 cm ) high x 17-1/4 in (43.8 cm) wide x 13 in (33cm) de[...]

  • Page 63

    Magnum VS –48 Vdc User’s Manual Page 58 9.6. Compliance NEBS Level 3 (Pending) Safety UL 60950 CE Marked to Low Voltage Directive (EN60950) EMC FCC Part 15 Class A EN55022 Class A, EN55024 EN61000-3-2, EN61000-3-3[...]

  • Page 64

    Magnum VS –48 Vdc User’s Manual Page 59 10 APC Worldwide Customer Support Customer Support for this or any other APC product is available at no charge. You can contact APC Customer Support in any of the following ways: • Use an APC web page to find answers to fr equently asked questions (FAQs), to access documents in the APC Knowledge Base, a[...]

  • Page 65

    Magnum VS –48 Vdc User’s Manual Page 60 11 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. APC PRODU[...]