APC XS 450 -48 - Manual

Magnum XS 450 Power System –48 VDC User’s Manual Page v Revision History Revision Date By Description 990-1557 Revision 1 20 Oct, 2003 JPF Initial Release 990-1557A Revision 2 30 MAR 2004 BET Update to include Battery Cabinet Table of Figures FIGURE 2.1-1 MAGNUM XS 450 POWER PLANT .....................

Magnum XS 450 Power System –48 VDC User’s Manual Page 1 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 d...

Magnum XS 450 Power System –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 install, maintain, and upgrade. The rectifier units are modular and truly “hot-pluggable” into the shelf assembly without any separate ...

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

Magnum XS 450 Power System –48 VDC User’s Manual Page 4 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 pro...

Magnum XS 450 Power System –48 VDC User’s Manual Page 5 3 Installation 3.1. Unpacking Equipment Remove equipment from packing material and inspect for shipping damage or missing items. It is important to report damage or material shortages to the shipping carrier while a representative is on site. I...

Magnum XS 450 Power System –48 VDC User’s Manual Page 7 Mounting The unit is self-supporting, but designed to be bolted to the floor of the housing structure. Figure 3.2-2 shows the footprint of the box frame and the mounting points with dimensions. Systems with multiple box frames are bolted togeth...

Magnum XS 450 Power System –48 VDC User’s Manual Page 8 3.3. AC Power Connections WARNING : Ensure that all of the external dc and ac circuit 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 bef...

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

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

Magnum XS 450 Power System –48 VDC User’s Manual Page 13 Rectifier Module Installation WARNING : Rectifier dc output circuits would be damaged if battery were installed incorrectly. Before rectifier installation, ensure proper battery polarity. Rectifier modules are hot-swappable. The rectifier modu...

Magnum XS 450 Power System –48 VDC User’s Manual Page 14 Merlin Gerin 28 Circuit Breaker Module Installation WARNING : Hazardous energy levels are present on bare conductors in the -48Vdc distribution connection area of the plant. Accidental shorting of distribution conductors can cause arcing and h...

Magnum XS 450 Power System –48 VDC User’s Manual Page 16 Figure 3.5-2 12 Circuit Breakers Module CIRCUIT BREAKER RATING ORDERING NUMBER Merlin Gerin C60HC 4 A 0M-3318 Merlin Gerin C60HC 10 A 0M-3314 Merlin Gerin C60HC 20 A 0M-3315 Merlin Gerin C60HC 32A 0M-3316 Merlin Gerin C60HC 40A 0M-3317 Merlin ...

Magnum XS 450 Power System –48 VDC User’s Manual Page 17 dc bus. Use M8 hardware to secure the buses together. Use M5 hardware to secure the front lip to the power system frame. Use M6 hardware to secure the rear of the module to the power system frame. Figure 3.5-3 NH2 Fuse Module Connect the LVD p...

Magnum XS 450 Power System –48 VDC User’s Manual Page 18 Hooking the load cables to a module used as a battery return will cause erroneous battery current readings. The dc load cable(s) should be sized to limit the voltage drop from the Magnum XS 450 Power System to the loads per system design requi...

Magnum XS 450 Power System –48 VDC User’s Manual Page 20 C60 28 26 25 23 22 20 19 17 16 14 C120 0 1 2 3 4 5 6 7 8 9 Total 28 27 27 26 26 25 25 24 24 23 C60 13 11 10 8 7 5 4 2 1 0 C120 10 11 12 13 14 15 16 17 18 19 Total 23 22 22 21 21 20 20 19 19 19 Table 3.7-1 Circuit Breaker Mix Table Installing c...

Magnum XS 450 Power System –48 VDC User’s Manual Page 22 Installing a fuse in the NH2 Fuse Module Insert the fuse into the fuse module until the tangs on each end of the fuse bottom out in the socket. Figure 3.7-6 NH2 Fuse Connections DC Load Return Module Installation The modules that are attached ...

Magnum XS 450 Power System –48 VDC User’s Manual Page 23 Figure 3.7-7 Large Load and Small Load Return Module DC Load Return cable connections The battery return module has a shunt installed and the load return modules do not. The small return has 40 pairs of M5 threaded holes on 1.59 cm (5/8 in.) c...

Magnum XS 450 Power System –48 VDC User’s Manual Page 24 Connect the LVD power wiring to the power bus observing proper polarity. Connect the LVD control cable to the customer interface bus. The alarm signal of each individual Battery Disconnect Switch is connected to the blade terminals of the swit...

Magnum XS 450 Power System –48 VDC User’s Manual Page 26 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 3.8-3 Typical location of Battery Temperature Probe 3.9 DC ...

Magnum XS 450 Power System –48 VDC User’s Manual Page 29 4 Commissioning 4.1 Pre-Commissioning Inspection Environment 1. Ensure the dc system environment is suitable for operation. 2. Ensure that there is sufficient clearance around the system for service. 3. Ensure that there is no sign of damage t...

Magnum XS 450 Power System –48 VDC User’s Manual Page 30 10. Check the torque of all battery inter- cell connector in accordance with the battery manufacturer’s specifications. 4.2 Commissioning Initial Set-up 1. Remove all rectifiers. 2. Disconnect battery by removing a link in each string or openi...

Magnum XS 450 Power System –48 VDC User’s Manual Page 31 1. Monitor battery current and verify that it is +/- 0.1 A. 2. Set battery maximum recharge setting by determining the entire battery string capacity and dividing by 10 hours. This setting will recharge the battery in 10 hours. 3. Enter this v...

Magnum XS 450 Power System –48 VDC User’s Manual Page 33 5 Operation 5.1 Technical Description The Magnum XS 450 Power System is designed to supply safe –54 Vdc primary power through the use of up to nine rectifier modules. If installed with an internal battery string, it will supply backup power as...

Magnum XS 450 Power System –48 VDC User’s Manual Page 35 5.5 Customer Interface Board Alarm Outputs (Output Relays) There are eight alarm output relays designated Relay 1 through Relay 6, Minor, and Major, respectively. These alarms reside on the controller and are connected to the external monitori...

Magnum XS 450 Power System –48 VDC User’s Manual Page 36 6 Preventive Maintenance Preventive Maintenance is typically performed on a quarterly basis. 6.1 Equipment 1. 4 Digit Voltmeter. 2. Clamp-on ampere meter. 3. Standard Insulated tools. 6.2 Inspection Environmental Inspection 1. Ensure the dc sy...

Magnum XS 450 Power System –48 VDC User’s Manual Page 37 2. Check the mechanical integrity of the battery framing, racking, or cabinet. Tighten where necessary. 3. If there is a battery disconnect device fitted, ensure that it is properly connected and protected. 4. Check the general appearance and ...

Magnum XS 450 Power System –48 VDC User’s Manual Page 38 5. After the fan has completely stopped spinning, insert a plastic pen or plastic screwdriver into the fan blade of one of the rectifiers and reinsert both rectifiers 6. Verify that you get the fan fail alarm on controller and the customer rem...

Magnum XS 450 Power System –48 VDC User’s Manual Page 39 Battery Preventive Maintenance Procedure The purpose of the preventive maintenance is to ensure that the battery is in good, working condition. The observations, measurements, and tests performed are designed to determine the “state of health”...

Magnum XS 450 Power System –48 VDC User’s Manual Page 40 7 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 configura...

Magnum XS 450 Power System –48 VDC User’s Manual Page 41 7.4 Compliance Safety IEC 60950, 3 rd Edition CE Marked to Low Voltage Directive (EN60950, 3 rd Edition) EMC FCC Part 15 Class A EN55022 Class A, EN55024 EN61000-3-2, EN61000-3-3

Magnum XS 450 Power System –48 VDC User’s Manual Page 42 8 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 frequently asked questio...

Magnum XS 450 Power System –48 VDC User’s Manual Page 43 9 Limited Product Warranty The limited warranty provided by American Power Conversion Corporation ("APC") in this Statement of Limited Factory Warranty applies only to Products Buyer purchases for your commercial or industrial use in t...