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DELTA MCS-600 Series Power System Installation, Operation and Maintenance Manual

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Delta MCS 600 Series Power System

Installation, Operations & Maintenance Manual

DELTA ELECTRONICS, INC.

Delta MCS-600 Power Shelf Installation, Operations and Maintenance Manual

Table of Contents
1. General
1.1 Using This Manual

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1.2 Safety Notice

2.

Product Description
2.1 Product Description 2.2 Product Main Features 2.3 System Specifications

3.

Power Supply Unit (PSU)
3.1 Description 3.2 Specifications 3.3 Operation and Adjustment 3.4 System Alarm 3.5 PSU Block Diagram 3.6 PSU Operating Principle

4. Alarm Control Unit
4.1 Description 4.2 Specifications

5. DC Distribution
5.1 5.2 DC Cabling Low Voltage Battery Disconnect

5.3 Battery Connections 5.4 Battery Temperature Probe

6.

Installation
6.1 Preliminary Inspection 6.2 System Mounting 6.3 Module Installation

6.4 Shelf Wiring 6.5 AC Input Connections

6.6 Battery String Connections 6.7 Temperature and Alarm Connections

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Customer Specification Confidential

Delta MCS-600 Power Shelf Installation, Operations and Maintenance Manual

Table of Contents
6.8 6.9 EXT. Breaker trip signal I/P Connector Wiring AC High Voltage Aux. Relay Output Wiring

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7. System Start –Up Procedure
7.1 Initial Start-Up Preparation 7.3 7.4 Basic Functional Verification 7.2 Start-Up DC Load Connections No Load

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7.5 System Functionality Check 7.6 System Operation

8.

System Alarms and Troubleshooting
8.1 8.2 8.3 8.4 8.5 AC Fail Voltage Alarm Description High Voltage Shutdown Alarm High Voltage Alarm Description Low Voltage Alarm Low Voltage Disconnect Alarm

8.6 Fuse Fail Alarm 8.7 Alarm Unit Fail

8.8 Rectifier Fail Alarm

9.

Maintenance
9.1 Cleaning and Maintenance 9.2 Removing and Replacing a Rectifier Unit

10. Acronyms and Abbreviations
A~J K~S T~Z

Attachment List
Figure 1: Functional Blocks Power Shelf Figure 1-1: Functional Blocks Power Shelf Figure 2: Control Supervisory Unit Figure 2-1: Control Supervisory Unit Figure 3: Switching Mode Rectifier

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Customer Specification Confidential

Delta MCS-600 Power Shelf Installation, Operations and Maintenance Manual

Table of Contents
Figure 4: Breaker Position Figure 5: Battery and Load Cable Connection Terminal Figure 5-1: Figure 6: Alarm Relay Output Position Figure 7: Power Shelf Rear View Figure 8: PSU Block Diagram Figure 9: ALU Block Diagram Figure 10: Schematics of ES-600 Series System (-48V)

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Customer Specification Confidential

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and other environmental conditions as noted in the specifications. including the ALU and the rectifier. are included. and confirmation.2 Safety Notice Delta Energy Systems is not liable for any hazards incurred by not following proper safety procedures. the –48V Power Supply Unit (PSU). The system has passed stringent system testing prior to shipment. 3. and the Distribution Module. This manual contains information related to the operation and maintenance of the Alarm Control Unit (ALU). The area must be free of any To avoid electrical hazard. Warnings are printed in bold.1 General Using This Manual This manual contains specifications and instructions to properly install and maintain the power supply system.Delta MCS-600 Power Shelf Installation. italic lettering. Operations and Maintenance Manual 1 1. Before installing the system. Component specifications and drawings are also included. and maintenance personnel should always follow these safety rules: 1. 1. Step-by-step procedures required for the installation and turn-up are detailed. Circuit breakers or fuses must be replaced with approved replacement circuit breakers meeting the original design specification. To avoid electrical shock. and system maintenance. adjustments. They alert the installation or maintenance craftsperson of a potential hazard to either the equipment or the craftsperson if the warning is not followed. The environment should be dust free and controlled by an AC system. The rectifier system requires a single ground point permanently connected to earth ground. Additional information is provided on system status and alarms. 4. troubleshooting. 2. REV. operations. flammable vapors or fluids. the AC breaker rating and type. An AC breaker must provide adequate isolation between the system input and commercial AC main. verify the AC input voltage and frequency. All equipment parameter setting. 7. Appendix A of this manual contains drawings. and maintenance procedures. 5. which are used for these purposes. the covers must not be removed on any component. Appendix B contains a simple block diagram for different functional blocks and systems schematic.: 03 1-1 Customer Specification Confidential . 6. as well as system monitoring. Installation. operation. All connections must be made per the latest issue of the applicable national and local codes.

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99PFC) High efficiency Temperature compensated float voltage control Alarm Control Unit Low Voltage Battery Disconnect (LVBD) Remote Monitoring and control 2. System level rectifier voltage settings.2 -48V System with Power Distribution and Rectifiers (1) (2) (3) (4) AC Input: System Capacity: Rectifier: Control and Supervisory 175VAC ~ 275VAC. Figure 1 shows different functional blocks of the system.3.3. and alarm thresholds are set from RMS or Web browser. 2. and a DC distribution module. 2. The ALU also provides automatic derating of the output power over the whole operating line voltages.: 03 2-1 Customer Specification Confidential . Operations and Maintenance Manual 2 Product Description 2. Max 40Amps. Max (2) System Capacity: 50Amps.1 -48V Standard Power Shelf Configuration (1) AC Input: 175VAC ~ 275VAC. N+1 redundancy (19” rack. equalize voltage. (3) Rectifier: -48V/10A×1~5 (4) Control and Supervisory Unit (5) Low Voltage Disconnect Switch: 100A×1 @ Single Pole at Battery Side (6) Battery Breaker: 100A×1 Figure 1 shows a front view of shelf.3 VDC at 10 Amps (HL)/5 Amps (LL). to power the load and maintain battery charge.Delta MCS-600 Power Shelf Installation. and alarms are displayed on the ALU. The system is controlled and monitored by the ALU.2 Product Main Features The Power Shelf has the following main features: -48 VDC/50 Amps. The rectifiers can operate from a universal range of AC line voltages. The High Line (HL) operations are defined at an AC line input range of 165 VAC-264 VAC.1 Product Description This power Shelf consists of modular rectifiers. 16Amps. The Low Line (LL) operations are defined at an AC line input range of 90 VAC-130 VAC. Each PSU can provide an output of –54. 20Amps. 5 rack space mounting) Modular design for scalable. 2.3 System Specifications The system specifications are provided in the following sections. Max. an Alarm Control Unit (ALU). Max. The system float voltage. Up to five rectifiers and an alarm unit can be equipped on a shelf containing an integrated distribution module. cost effective expansion Front access for simple installation and maintenance High power density Active Power Factor Correction (>. system status. -48V/10A×1~4 REV.

5% <0.: 03 2-2 Customer Specification Confidential .Delta MCS-600 Power Shelf Installation.3. LL Load regulation Line regulation Current Limit Current share Noise: Audio band Wide band Acoustic Battery breakers Temperature Compensation <2mv <10 mVrms <55 dBA 1.3.3.99 <5% >90% 2.3. Operations and Maintenance Manual (5) Load Distribution: (6) Low Voltage Disconnect Switch: (7) Battery Breaker: Figure 1-1 shows a front view of shelf.5Kw <0. HL Each module.3 Electrical Data The system electrical data is provided in the following tables.1% 110% <5% 40-60 VDC Value REV. Table 2 System Output Specifications Specification DC Volts Power Each module. 10A Breaker×4 @ Single Pole 100A×1 @ Single Pole at Battery Side 100A×1 2.1 Input Table 1 displays the system input specifications. Table 1 System Input Specifications Specification Nominal range Operational range Frequency Power Factor THD Efficiency Value 90-275 VAC 175-275 VAC 45-65 Hz >0. 2.3. LL System. 50 Amps CB 50 to 100 mV/string 600W 300W 3Kw 1. HL System.2 Output Table 2 displays the system output specifications.

Class B ANSI/IEEE C62.22 in.4 Mechanical Data Table 3 displays the system mechanical data. FCC Part 15.3.4mm) 19 in. (483mm) 2.000 ft.5 Environmental Data Table 4 displays the system environmental data. Table 3 System Mechanical Data Dimension Height Depth Width Value 5.3.3. (304.3 Status/Alarm Indicators The Power Shelf has the following status/alarm indicators: Load Current. Table 4 System Environmental Data Specification Operating temperature -0℃ to +50℃ -20℃ to +65℃ OPTION Storage temperature Humidity Altitude Weight EMI/FRI Lightning/surge Seismic Safety -40℃ to +85℃ 0% to 95% RH -300 ft. % of Output AC ON Rectifier Fail Alarm (RFA) Current Limit (CL) Float/Equalize (FL/EQU) Major Alarm (MAJ) Minor Alarm (MIN) High Voltage Alarm (HV) High Voltage Shutdown (HVSD) Low Voltage Alarm (LV) Low Voltage Disconnect Open (LVDS OPEN) Fuse Blown (FUSE ALM) AC Fail (AC FAIL) 2.6mm) 12 in. Class B and CISPR 22.41-1. Approximately 48 lbs. Operations and Maintenance Manual 2. to 10.: 03 2-3 Customer Specification Confidential .3.3. and IEC 1000-4-5 Bellcore GR-63-CORE. Zone 4 CUL and UL Listed and CE Marked Value REV.Delta MCS-600 Power Shelf Installation. (132.3.

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Each module is equipped with an AC switch located at the front of the module.1 Input Table 5 displays the rectifier input specifications. Single Phase. Cold Start 3 to 10 seconds Fuse Input Current Line Frequency Power Factor THD Efficiency Inrush Current Start Time Delay (Walk-In) Protection 3.1. Warning: In the absence of the ALU. Each rectifier unit is swappable with front access for ease of maintenance without system shutdown. Full Load. 3. the rectifier can operate on a stand-alone basis.2. Exceeding the 50% load limit at Low Line may damage the rectifiers. the automatic derating of the rectifiers at Low Line is not effective. The rectifier unit has an active power factor correction of greater than 0. 3. The modular design provides the flexibility to configure and expand the system as the load demand increases. Full Load <9 Amps (peak).2.99. However. For Low operation. Table 6 Rectifier Output Specifications REV. at 220 VAC Input.: 03 3-1 Customer Specification Confidential . Full Load 45 to 65 Hz >0.Delta MCS-600 Power Shelf Installation. providing uninterrupted service.2. 3. the output is derated to 5 Amps. (during 175 to 120 VAC derated to 70% Load. Full Load <5%. if this ALU is removed or nonfunctional. 220 VAC. This derating is automatically activated from the Alarm Control Unit (ALU).2 Output Table 6 displays the rectifier output specifications. Table 5 Rectifier Input Specifications Specification Input Voltage Value 90 VAC to 275 VAC.2 Specifications Detailed rectifier specifications are provided in the following sections. Full Load >90%.1 Power Supply Unit (PSU) Description This rectifier units are rated at 10 Amps at –48 VDC when operated from high line. during 120 to 90 VAC derated to 50% Load) 4 Amps at 176 VAC.1.99 for maximum AC utilization. Operations and Maintenance Manual 3 3. at 220 VAC Input.1 Electrical Detailed electrical specifications for the rectifier are provided in this section.

of Rated Output Current Value 40 to 60 VDC [factory preset at –54.5% (Load 0 to 100%) <0.Delta MCS-600 Power Shelf Installation.I-) Float Voltage (FLO) Current Limit (CL) Current Variable Resistor or Setting on ALU Variable Resistor or Setting on ALU Description Automatic Shutdown and Recovery Automatic Shutdown and Recovery No Damage Automatic Shutdown and Recovery Automatic Shutdown and Recovery REV. Table 8 Adjustments Adjustment Test Points (I+.1.2.4 Adjustments Table 8 displays the adjustments. Operations and Maintenance Manual Specification DC Output Voltage Output Power Regulation: Load Line Current Limit Noise: Audio Band Wide Band Acoustic Current Sharing Dynamic Response Protection 3. 10 Amps (HL) / 5 Amps (LL)] 600 W Maximum High Output Voltage (Exceeds Automatic Shutdown and Latch Preset Value) Over Current/Output Short Over Temperature Brownout AC Input Voltage High AC Input Voltage Low 3. Table 7 Protection Specifications Condition Response <2mV <10 mVrms (10 KHz to 100 MHz) <55 dBA @ 1M <5% of Rated Output Current 10% to 90% Load Change Overshoot ≤5% Rated Output Voltage Recovery Time <1 ms to ≤1% Rated Output Voltage Fuse <0.2.3 Protection Table 7 displays the protection specifications.1% 110% Max.: 03 3-2 Customer Specification Confidential .1.3 VDC.

IEC 801-3 Level 3 Conforms to EN 61000-4-4.Delta MCS-600 Power Shelf Installation.41.4 Mechanical Data Color Amber Green Red Function CL AC RFA Description Current Limit AC ON Rectifier Failure Alarm Value -4 to +149℉ (-20℃ to +65℃) -40 to +185℉ (-40℃ to +85℃) 0% to 95% Relative Humidity Noncondensing -500 ft. per module REV.) Conforms to EN 55022.3 Status/Alarm Indicators Table 10 displays the status alarm indicators Table 10 Status Alarm Indicators Indicator LED LED LED 3. Operations and Maintenance Manual 3. IEC 801-2 Level 4 Conforms to IEC 1000-4-3. UL/CUL and UL Listed and CE Marked >150 K hours Fan cooling 228 BTU/hour max. 1991 B3.2. IEC 1000-4-5 Level Special (6KV) Meets IEC 950. IEC 1000-4-4.000 ft. 2 Kg (4. IEC 801-4 Level 4 Conforms to IEC 1000-4-6 Level 3 Conforms to ANS/IEEE C62.2 Environmental Table 9 displays the environmental specifications. and CISPR 22 Class B Conforms to EN 61000-3-2/A12. to 10. Table 9 Environmental Specifications Specification Operating temperature Storage temperature Humidity Altitude Weight EMI/FRI suppression Current harmonic Voltage fluctuation Electrostatic discharge Radiated susceptibility Electrical fast transients Conducted susceptibility Lightning/surge Safety MTBF Cooling Heat dissipation 3.-1. IEC 555-2 Class A Conforms to EN 61000-3-3. BS 6527 FCC Part 15 Subpart J.2. EN 60555-2.2. IEC 1000-4-2.: 03 3-3 Customer Specification Confidential . EN60950.4 lbs. EN 60555-3 Conforms to EN 61000-4-2.

6mm) 3.02V. REV. Remove the ALU. Notes: 1.Delta MCS-600 Power Shelf Installation. Float voltage adjustment 2. 3.3. reference.57 in.2 in. (132mm) 9. Turning the variable resistor adjustment point clockwise increases the value.1 Start-Up To start up the system. perform the following steps: 1. adjustments must be made with no load. 3.output voltage connecter. and the batteries disconnected to ensure adjustment accuracy. Current limit adjustment 3. The following components are located on each rectifier panel: 1.5 in.: 03 3-4 Customer Specification Confidential . All Float Voltage Adjustment Verify the required float voltage setting per battery manufacturer specification. 3. To adjust the float voltage. Alarm indicators Figure 3 shows different indicators and adjustment points on this unit.3 Operation and Adjustment All operating adjustments are made at the front panel of each rectifier. 3. Place the digital multimeter probe in the V+ and V. Rectifier adjustments must be done sequentially from the first through the fourth rectifier with AC applied.1mm) 2. the RFA LED extinguishes. (243. When the setting is completed. 3. 2. Current test points 4. Table 11 Rectifier Mechanical Data Dimension Height Depth Width Value 5. A digital multimeter and a small screwdriver are required to perform this procedure. Adjust the float voltage by using a screwdriver to turn the FL point to the voltage value as shown on the meter.3 Current Limit Setting Users should only use it for their Warning: Current limit setting is not intended to be adjusted in the field.3.and FL point. If the factory setting differs from the battery manufacturer recommended setting. perform the following steps: 1. The tolerance error should not exceed 0. Located the float voltage access point (FL) at the front of the rectifier. V. Operations and Maintenance Manual Table 11 displays the rectifier mechanical data. temperature and voltage compensation must be reset to the default value.2 Aproximately 3 to 8 seconds after the AC applied. and counterclockwise 2. (63. Refer to attachment 7-1 and 7-2 (rectifier front view) for the location of V+. the ALU float voltage parameter and each rectifier’s float voltage must be adjusted to the new setting.3.

The factory setting is always the maximum value of 110%.99 and the Total Harmonic Distortion (THD) at <5%. and to prevent noise reverse to the source circuit.6 PSU Operating Principle After applying the incoming line voltage to the rectifier. I. current is applied to the EMI filter and circulates through protection components such as the AC circuit breaker and the fuse. This PFC stage The 400 VDC bus voltage is modulated at a frequency higher than 75 KHz and stepped down through a transformer.Delta MCS-600 Power Shelf Installation.4 System Alarm During an alarm condition. Place a small screwdriver in the CL adjustment point. closes the RFA alarm contacts. Output of this transformer is rectified and filtered to provide the output DC voltage. At the rectifier. to eliminate the high frequency noise from input current. and lights the alarm LEDs. Operations and Maintenance Manual Current limit adjustment is made by turning the CL variable resistor with the digital multimeter probes in the I+. place the digital multimeter probes in the I+. The major functions of the protection devices are to prevent the rectifier from being damaged by surge voltage. 3.test points. to efficiently reduce the noise of differential mode and common mode. The AC input voltage is rectified and converted to a 400 VDC bus through a PFC boost stage.test points. This current limit is set at the factory. For a 10-Amp rectifier. the faulty rectifier illuminates its RFA light on the front panel. The following adjustment procedure is for reference only: 1. Turn the variable resistor counterclockwise to increase the value.1×10=11 Amps. 3. The rectifier fail alarm signal is sent to the ALU. 3. I. REV. 2. maintains the Power Factor at >.: 03 3-5 Customer Specification Confidential . which processes the alarm. Turn the variable resistor clockwise to decrease the current limit value. the computation for the current limit is 1. 3.5 PSU Block Diagram Refer to Figure 8.

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2 Push Buttons This alarm unit has 3 push buttons on the front panel.5 Amps Table 14 displays the Push Buttons Settings Description REV. Operations and Maintenance Manual 4 4.2 Specifications 4. 50% 70% 100% Output 4. low voltage disconnect voltage threshold settings. These push buttons are used to control the alarm unit. an equalize charge timer.Delta MCS-600 Power Shelf Installation.: 03 4-1 Customer Specification Confidential . the ALU automatically derates the system output current according to the following table: Table 12 Voltage Ranges Input Voltage Range 90-120 VAC 121-175 VAC 176-275 VAC The module is hot-swappable.2. temperature compensation voltage settings. alarm threshold adjustments.1 Input Characteristics Table 13 displays the input characteristics.2. Table 13 Input Characteristics Characteristic Input Voltage Range Input Current 4.1 Alarm Control Unit Description The Alarm Control Unit (ALU) with RS232 & LAN interface and remote monitoring function provides output alarms. Following are possible functions these buttons will act: Control FL/EQU HVSD RST SMR RST Value 20V to 59.5V <0. In addition. float and equalize voltage adjustments. and system alarm LEDs.

if the button is pushed at this time. Table 15 ALU Indicators Indicator LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 Color Green Yellow Red Red Yellow Red Red Red Red Red Function FL EQU HV LV MIN MAJ HVSD AC FAIL FUSE ALM System Float State System Equalize State DC High Voltage Alarm-Minor DC Low Voltage Alarm-Minor System Minor Alarm System Major Alarm High Voltage Shutdown (DC) Loss of AC Input DC Output Fuse Open or Breaker SW. Operations and Maintenance Manual FL/EQU .2. 4. However. button is used to reset alarm state. the system will stop sending the warning.: 03 4-2 Customer Specification Confidential .Function SMR RST .3 Indicators Table 15 displays the ALU indicators.5 ALU Alarm Signal Descriptions REV.2.2.Function    This button is used to manually select SMR into float or equalize state.Delta MCS-600 Power Shelf Installation.Function HVSD RST . This System will detect RFA warning when SMRs are turned off.(Please refer to Figure 6) Table 16 Relay Output Relay Relay1 Relay2 Relay3 Relay4 Relay5 Relay6 Relay7 Relay8 Function ACF MAJ HVSD HV LV LVD FA MIN AC Failure Major Alarm High Voltage Shutdown DC High Voltage Alarm-Minor DC Low Voltage Alarm-Minor Low Voltage Disconnect Open Fuse Alarm Minor Alarm Description 4. Trip Description LVDS OPEN Low Voltage Disconnect Open 4. When SMRs shut down resulting from DC high voltage.4 Relay Output Table 16 displays the relay output.

7 Environmental Table 19 displays the environmental specifications.4mm) 1. Table 19 Environmental Specifications Specification Operating temperature Storage temperature Humidity Value 32℉ to +122℉ (0℃ to +50℃) -4℉ to +149℉ (-20℃ to +65℃) -40℉ to +185℉ (-40℃ to +85℃) 0% to 95% Relative Humidity Noncondensing Value 5. (2) Current Limit Alarm. Operations and Maintenance Manual MAJ: Major Alarm (1) 2 or above rectifiers fail.85 in. (3) DC High Voltage Alarm. (2) Temperature sensor disconnect.6 Physical Table 18 displays the ALU mechanical data. The alarm condition exists when the DC output voltage is lower than the parameter setting. The alarm condition exists when the DC output voltage is lower than the threshold voltage. (242.2. MIN: HV: LV: AC Fail: LVDS: Fuse Fail: The alarm condition exists when the battery switch trip off or the DC Load output fuse is blown. The alarm condition exists when the DC output voltage is higher than the parameter setting. (4) DC Low Voltage Alarm.Delta MCS-600 Power Shelf Installation.2 in. (3) AC Low Voltage Alarm. Table 18 ALU Mechanical Data Dimension Height Depth Width 4. (4) AC High Voltage Alarm.2. (8) Breaker or Fuse Alarm.54 in. Minor Alarm (1) One rectifier fail. (5) LVDS Trip Alarm. (7) HVSD Alarm. The alarm condition exists when the AC voltage is absent. (47mm) REV. (6) Battery over temperature. 4. (132mm) 9.: 03 4-3 Customer Specification Confidential .

Use Internet Web server function (RJ45)-(Optional) 4.Delta MCS-600 Power Shelf Installation.: 03 4-4 Customer Specification Confidential . Use RS232 Interface. Operations and Maintenance Manual Altitude Weight ESD -500 to 10. 2.8 Remote monitoring and control The ALU provide the flowing remote monitoring methods. 4. REV. 1.4 lbs.2. (2Kg) IEC 1000-4-2 (Contact 4KV Air 8KV) 4.9 Parameter Modify Enter the Remote monitoring software or use the internet Brower to modify the parameter.000 ft.2.

4 Battery Temperature Probe Connection The battery temperature probe senses the battery temperature and sends the signal back to the ALU.1 DC Cabling You can find DC output which marked Load + and Load – behind the shelf of the left hand side. Operations and Maintenance Manual 5 DC Distribution 5. Please refer to figure 5. To connect the temperature sensor. 2. Attach the copper lug sensor to the center position. it disconnects the batteries from the system bus. 5. Connect the sensor to the connector labeled TB located behind the shelf. 5. On the top of power distribution module.: 03 6-1 Customer Specification Confidential . Please refer to Figure 5-1.Delta MCS-600 Power Shelf Installation.3 Battery Connections The battery connections which are behind the distribution module should be made through the breaker. A temperature sensor is included with each Power Shelf. The temperature is used to determine the temperature compensation voltage.2 Low Voltage Battery Disconnect The low voltage disconnect contactor is installed in front of the battery connection bus. Please refer to 5. Figure 5. REV. perform the following steps: 1. When LVDS opens. BAT+ for battery positive and BAT – for battery negative. Battery and system bus are connected in parallel. Please refer to figure 7.

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all power modules can be removed from the shelf when mounting the shelf onto a rack.4 Shelf Wiring The shelf comes fully assembled and is equipped with the ALU and the distribution module. 2. The shelf typically is shipped with the ALU and the distribution module. 1) Ensure that the AC power is isolation. Installation and Please refer to 4. The system operates at AC voltages that can produce fatal electrical shock. maintenance personnel must observe all safety precautions. to install the rectifier and ALU.6 Battery String Connections Warning: 1. or module wiring is required. 3) Loosen the fixed thumbscrew on the ALU panel and pull the ALU out. This system allows the relay rack to be installed as close to a rear wall as is necessary for the installation.1 Preliminary Inspection Prior to removing the system from the crate. 4) Reverse the procedure. note any damage to the carton. 6. contact the carrier immediately. 6. 2.5 AC Input Connections The power system is equipped with one power terminal located at the center rear of the shelf. While connecting the battery cables inside the distribution module. Failure to connect the battery cables correctly to the system can cause damage to batteries and the system. connections are made at the factory.: 03 6-1 Customer Specification Confidential . figure 7. make sure REV. The front of the system should be clear of all obstruction and allow room for proper ventilation. No internal. Warning: 1. All internal 6. If any damage is noted. installation. 6. Each shelf requires a (2) properly grounded AC input feeds supplied by Delta.3 Module Installation In order to reduce the weight of the system. and maintenance. Failure to use the appropriate power wire causes safety hazards.2 System Mounting The power system is typically shipped with the shelf in one carton and rectifiers in individual cartons. 2) Loosen the fixed thumbscrew on the rectifier and pull the rectifier out. 3.Delta MCS-600 Power Shelf Installation. 6. shelf. Confirm the operating voltage and proper grounding of the incoming line before proceeding. Verify the polarity of the battery leads prior to connecting the battery cables to the system. The module can be mounted in a 19”relay rack provided by the customer. Operations and Maintenance Manual 6 Installation 6. Remove the system from the packaging and inspect the shelf and components for any dents or damage.

6. Warning: All external circuits connected to these alarm relay terminals must be secondary and properly isolated from the incoming line.4. Table 21 Alarm Terminal Block Pin Assignments Alarm ACF MAJ HVSD HV LV LVD FA MIN AC Fail Major High Voltage Shutdown High Voltage Alarm Low Voltage Alarm Low Voltage Disconnect Fuse Alarm Minor This contact is capable of Description 2. Breaker trip signal I/P” connector. The “FUSE ALM” LED on the front panel of ALU will light up when the breaker open.2 External Alarm Connections The connection method please refer to section 1.7 Temperature and Alarm Connections 6.1 Battery Temperature Sensors One (1) battery sensor cable is provided with each system.7.8 Connect the AUX. carrying 1 Amp DC at 30VDC on a continuous basis. the AC lines are turned off and the battery cables are disconnected at the battery end). Connect the positive battery cable(s) to the BATT + and connect the negative battery cable(s) to the BATT -. 6. Operations and Maintenance Manual the system is completely disenergized (that is. PDU signal cables to the rear of the shelf which are mark “EXT.7. The system voltage (rectifier output voltage) is –48 VDC. Please refer to Figure7. Each alarm connection is provided with a normally close relay contact. 3. 6. 5. 6. REV.: 03 6-2 Customer Specification Confidential . 3.9 AC High Voltage Aux. Relay output wiring The connection point of “AC High Voltage Trigger Relay” which is on the rear of shelf will close when the AC input voltage is higher than the setting value normally it’s open.Delta MCS-600 Power Shelf Installation.

The “FUSE ALM” LED on the panel light because the battery breaker is switched to “OFF”. To start up the system.5 System Functionality Check Control and supervisory functional testing can be performed at the ALU after the basic functional testing is completed and the DC load is connected. 3. Verify all connections prior to starting this section. 7.1 Initial Start-Up Preparation 7.4 DC Load Connections 1.5. Connect the positive load wires to the Load +. 7. Confirm the operating voltage before proceeding.Delta MCS-600 Power Shelf Installation. PDU in the system. Check the ALU for alarm and status conditions. 7. Ensure the battery DC circuit breaker is switched to the “OFF” position 7. 7. Please refer to section 5 DC Distribution. Ensure that the AC line is properly grounded. 2. 4. Verify that the battery is not connected to the system battery bus or ensure the battery switch in the “OFF” position. Connect the negative load cable to the Load -. 2. 3.: 03 7-1 Customer Specification Confidential . REV.6 System Operation Upon completion of the system functional testing.3 Basic Functional Verification After system start-up. 7. perform the following steps: 1.1 System Status and Alarms Check the status of the equipment by viewing the ALU alarm and status LEDs. If there is the AUX. 2. 2.2 No Load Start-Up The system can be started up without a load. 3. Compare the rectifier DC voltage readings at the ALU with the output voltage of each rectifier by using digital multimeter (measure at the V+ and V– points located on the front of each rectifier). Check the ALU status and alarm LEDs. basic functional verification should proceed as follows: 1. Operations and Maintenance Manual 7 System Start-Up Procedure 1. the system is operational. Switch all DC distribution circuit breakers to the “OFF” position and/or remove all the fuses.

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When the system voltage exceeds the HV setting value. check the rectifier input breakers in the AC panel for a tripped or failed breaker. 4. Restart the rectifiers by resetting the HVSD RST button located on the ALU. and activates the HV alarm contact. 8. 3. The AC Fail LED on the ALU panel lights up. and returns the contact to the normally closed position. At this point. When the DC voltage falls below the HVSD threshold voltage. The ALU lights the HVSD LED located on the ALU panel and shuts down each rectifier. the ALU sends an AC Fail alarm signal and activates the dry contact. the system equalize voltage exceeding the HVSD threshold. 8. or temperature compensation exceeding the HVSD threshold setting. Verify that the equalize voltage setting does not exceed the HVSD threshold setting. 1. If this connection is missing. then the system recovers. the system generates an AC Fail alarm. 8.2. and closes the normally closed set of contacts. and push the HVSD RST Button.1 8. the ALU extinguishes the HV LED and deactivates the HV alarm contact. If commercial AC is detected at the AC panel. Warning: The ALU senses the AC line through the AC Input terminal.: 03 8-1 Customer Specification Confidential .2 Troubleshooting The AC Fail alarm is normally caused by a commercial AC interruption due to a storm or maintenance.1 Description When the ALU detects the output DC voltage exceeding the HVSD threshold setting. REV.3 High Voltage Alarm Description 8.Delta MCS-600 Power Shelf Installation. 8. returns the rectifiers to service.1 System Alarms and Troubleshooting AC Fail Voltage Alarm Description Description If the ALU detects an input AC voltage below 50 VAC.1. the ALU sends the HV alarm signal.3. Verify the output voltage of each rectifier in both float and equalize. When the system voltage decreases below the threshold setting. Operations and Maintenance Manual 8 8. When AC voltage is restored to the nominal input voltage. The ALU extinguishes the HVSD LED. the ALU extinguishes the AC Fail LED.2 Troubleshooting High voltage shutdown occurs when the output voltage exceeds the HVSD threshold.1. Ensure that Temp Comp does not exceed the HVSD threshold setting when operating in cold temperatures.2 High Voltage Shutdown Alarm 8. lights the HV LED located on the ALU panel.2. the ALU sends an HVSD alarm signal and activates the dry contact. The rectifiers remain on line during this minor alarm condition. Verify the temperature compensation voltage setting. This can be caused by a rectifier failure. 2. the system is running on reserve batteries.1 Description The High Voltage alarm (HV) is a minor alarm activated when the DC output voltage exceeds the HV threshold setting.

6.3.2 Troubleshooting To troubleshoot the fuse/circuit breaker fail alarm condition. 8. 8.4. During this alarm condition. the ALU sends the alarm condition.2 Troubleshooting The LV alarm condition occurs during a brownout condition or prior to a complete AC Fail condition caused by commercial AC problem conditions.4 Low Voltage Alarm Description The Low Voltage alarm (LV) is a minor alarm activated when the DC output voltage decreases below the LV threshold setting. The rectifiers remain on line during this minor alarm condition.6 Fuse Fail Alarm 8. and opens the LVDS contactor. 8.5 Low Voltage Disconnect Alarm Description During an AC Fail condition. check the LVBD coil windings. one of the following is occurring: 1. and activates the LV alarm contact. Operations and Maintenance Manual 8. With a digital multimeter. Another probable cause that the temperature compensation voltage exceeds the HV threshold during cold temperature operation. Another probable cause is that the temperature compensation voltage decreases the float voltage below the LV threshold during hot temperature operation. the LVBD recovers automatically. the rectifiers are shut down and the reserve batteries begin to discharge. The reconnect voltage additive (47V) is factory set.5. When the battery cells discharge below the LVD setting. When the AC recovers.4.5.1 8. the ALU extinguishes the LV LED and deactivates the LV alarm contact. activates the LVDS OPEN alarm contact.1 Description If the DC load output fuse opens or battery switch trip off.1 8. lights the LED on the ALU panel. and activates the Fuse Fail alarm. The ALU extinguishes the LVD LED and resets the normally closed set of alarm contacts. When the system voltage decreases below the LV LED located on the ALU panel. the ALU lights the LVD LED on the ALU panel. Swap out the ALU with a spare and verify voltage settings. 8. When the system voltage increases above the threshold setting. During this alarm condition.: 03 8-2 Customer Specification Confidential . 8. the system continues to operate. The ALU may be faulty. 2.2 Troubleshooting If the battery disconnect switch remains open after voltage is restored to the rectifiers. the system continues to operate. 8.Delta MCS-600 Power Shelf Installation.6.2 Troubleshooting The HV alarm is usually caused when the equalize voltage exceeds the HV threshold setting. The LVBD coil windings may be open. perform the following steps: REV.

8. If the device rating is higher than the branch load wire rating. The LVBD does not open during an ALU failure. the rectifiers status changes from equalize to float or remains in the float condition. (2) (3) There are no serviceable parts. If you want to ignore the MAJ or MIN alarm when you pull out the rectifiers from the slots. If the branch load exceeds the fuse/circuit breaker rating. When two rectifiers fail. the MAJ alarm contact is opened. the condition described in item (2) will be cleared. turn it on. Verify that the fuse/circuit breaker is the proper size (use 80% derating guide). the device must be changed to a higher rating. 2. Replace if blown. Warning: Ensure that the device rating does not exceed the branch load wire capacity. Failure to protect the branch load wire may result in overheating and fire. Replace the blown fuse with a fuse with the same rating or of the corrected value. circuit breaker. and the MAJ LED lights. If you insert the above rectifier back to the slot. In case of a If the fuse/circuit breaker continues to trip.1 Description During an ALU fail condition. Check the DC input connectors for proper connections. and the MIN LED on the ALU lights. The system will alarm in the “MIN” mode. perform the following steps: 1. 2. 8. REV. Check the DC branch load to ensure tat the fuse/ circuit breaker is the correct size.: 03 8-3 Customer Specification Confidential . 2. perform the following steps: 1. 8. Rectifier Fail Alarm (1) If one rectifier fails. Operations and Maintenance Manual 1.7. If necessary replace with the correct size fuse. 3.2 Troubleshooting To troubleshoot the ALU fail condition.7. the branch load wire must be changed to a larger wire. During an ALU failure.Delta MCS-600 Power Shelf Installation. the ALU fail and status LEDs are extinguished. Verify that the external fault that might cause fuse/circuit breaker tripping is removed.7 Alarm Unit Fail 8. and all alarm contacts open. 3. just please press the SMR RST button on the ALU. the MIN contacts open. Warning: Do not open the rectifier unit. That means if we repeat to pull out and insert in and pull out the rectifier. Check the input fuse located on the rear of the ALU. 3. then pull out after the “FL” LED on the SMR panel light up.8 Replace with a spare and send the faulty unit to Delta for repair. Install a fuse/circuit breaker with a higher rating.

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For periodic cleaning. AC ON LED lights. Place the rectifier on the shelf. Loosen the two captive retaining screws located on the top and the bottom of the front panel. Pull out the rectifier unit slowly from the shelf. equipment can result in serious equipment damage.1 Removing a Rectifier Warning: Do not touch the DC output bus when pulling out the PSU module. ensuring that the rails are on the track. Using a spray cleanser directly on the 9. Warning: Do not use a spray cleanser to clean the equipment. REV. and the rectifiers.: 03 9-1 Customer Specification Confidential . If necessary. remove and reset the unit. 9.2 Removing and Replacing a Rectifier Unit 9. If does not slide in and connect easily. Do not use organic cleanser or volatile solvent because corrosion damage may occur.Delta MCS-600 Power Shelf Installation. 2. use a gentle detergent to clean. 1. perform the following steps: 1. Warning: Do not force the module into the slot.2 Replacing a Rectifier To replace a rectifier. To remove a rectifier.1. If necessary. Install the rectifier unit carefully. unless the system is being operated in a severely harsh environment (dusty environment). 3.2 Periodic Maintenance Periodic maintenance is not required for normal operation. The front panels and the cover of the DC distribution cabinet were treated with a special coating. If necessary. soft cloth and gently wipe the front of the distribution module.1 Maintenance Cleaning and Maintenance General Special maintenance is not necessary for this system. perform the following steps. 9. brush the dust from the cover and panel. Operations and Maintenance Manual 9 9.1.2.1 9. 2. On the front of the rectifier. wipe dust from the front of the power system using a lint free. Lock the rectifier into position by screwing in the two captive retaining screws located at the top and the bottom of the rectifier.2. the ALU. use a gentle cleanser or a lightly dampened lint free cloth to remove any dirt or smudges.

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International Electronics Commission Institute of Electrical and Electronics Engineers Inch --.A --- --.D ----.G --GND Ground --.B --BS BTU British Standard British Thermal Unit --. Fahrenheit Federal Communications Commission Foot --.Delta MCS-600 Power Shelf Installation.F --F FCC Ft.C --C CB CE CISPR CL CUL Centigrade Circuit Breaker European Community International Special Committee on Radio Interference Current Limit Canadian Underwriters Laboratory --.: 03 10-1 Customer Specification Confidential .K --REV.J ----.E --EMI ESD Electro-Magnetic Interference Electrostatic Discharge --.I --IEC IEEE In. Operations and Maintenance Manual 10 Acronyms and Abbreviations ALU Amp ANSI Alarm Control Unit Ampere American National Standards Institute --.H --HL HV HVSD Hz High Line High Voltage High Voltage Shutdown Hertz --.

MHz Mm Ms MTBF MV mVrms Meter Maximum Megahertz Millimeter Millisecond Mean Time Between Failure Millivolt Millivolt root root mean square --. National Electrical Manufacturers Association Number --.R --RFA RFI RH RMA Rectifier Failure Alarm Radio Frequency Interference Relative Humidity Return Material Authorization --. LED LL LV LVD LVBD LVDS Pound Light-Emitting Diode Low Line Low Voltage Low Voltage Disconnect Low Voltage Battery Disconnect Low Voltage Disconnect Switch --.Delta MCS-600 Power Shelf Installation.O ----. KHz KHz KV KW Kilogram Kilohertz Kilohertz Kilovolt Kilowatt --.N --NEMA No.S --REV.: 03 10-2 Customer Specification Confidential .L --Lb.M --M Max. Operations and Maintenance Manual Kg.Q --Qty.P --PF PFC PSU Power Factor Power Factor Correction Power Supply Unit --. Quantity --.

T --TB THD Terminal Block Total Harmonic Distortion --.: 03 10-3 Customer Specification Confidential .V --V VAC VDC Volt Volts AC Volts DC --. Operations and Maintenance Manual --.X ----.Y ----.Z --- REV.U --UL Underwriters Laboratory --.Delta MCS-600 Power Shelf Installation.W --W Watt --.

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: 03 Alarm Control Unit Power Supply Units PDU Module LVDS Module A-1 Customer Specification Confidential .Delta MCS-600 Power Shelf Installation. Operations and Maintenance Manual Figure 1: Functional Blocks Power Shelf REV.

Delta MCS-600 Power Shelf Installation.: 03 Alarm Control Unit Power Supply Units PDU Module LVDS Module A-2 Customer Specification Confidential . Operations and Maintenance Manual Figure 1-1: Functional Blocks Power Shelf REV.

Delta MCS-600 Power Shelf Installation.: 03 A-3 Customer Specification Confidential . Operations and Maintenance Manual Figure 2: Control Supervisory Unit System Voltage Measurment System Current Measurement Manual Float/ Equalizing Button High Voltage Shut Down Reset SMR RFA Warning Reset Alarm/Status Indicator LEDS RS232 Interface REV.

Operations and Maintenance Manual Figure 2-2: Control Supervisory Unit System Voltage Measurment System Current Measurement Manual Float/ Equalizing Button High Voltage Shut Down Reset SMR RFA Warning Reset Alarm/Status Indicator LEDS RS232 Interface LAN Interface REV.Delta MCS-600 Power Shelf Installation.: 03 A-4 Customer Specification Confidential .

Operations and Maintenance Manual Figure 3: Switching Mode Rectifier REV.Delta MCS-600 Power Shelf Installation.: 03 A-5 Customer Specification Confidential .

Operations and Maintenance Manual Figure 4: Breaker Position REV.Delta MCS-600 Power Shelf Installation.: 03 A-6 Customer Specification Confidential .

Operations and Maintenance Manual Figure 5: Battery And Load Cable Connection Terminal REV.: 03 A-7 Customer Specification Confidential .Delta MCS-600 Power Shelf Installation.

Operations and Maintenance Manual Figure 5-1: Battery And Load Cable Connection Terminal Load1 Load2 Load3 Load4 REV.: 03 A-8 Customer Specification Confidential .Delta MCS-600 Power Shelf Installation.

Delta MCS-600 Power Shelf Installation.: 03 A-9 Customer Specification Confidential . Operations and Maintenance Manual Figure 6: Alarm Relay Output Position REV.

Delta MCS-600 Power Shelf Installation. Operations and Maintenance Manual Figure 7: Power Shelf Rear View REV.: 03 A-10 Customer Specification Confidential .

T CSU Delta MCS-600 Power Shelf Customer Specification Confidential Installation.: 03 Figure 8: Vo + • L • • • Output Filter PFC Boost Converter PSU Block Diagram Vo - N • Input Fuse Inrush C.K.REV.T.K. and Bridge Insulated Half Bridge DC/DC Converter FG A-11 PFC Controller and Protection C.. Operations and Maintenance Manual Auxiliary Power .T DC/DC Controller and Protection C.K. EMI Filter.

Operations and Maintenance Manual SMR Fail Reset .REV. Temperature DC Voltage AC voltage Current Alarm Output Relay and LED Indicator LVDS Contact Control Current Limit Signal PWM Voltage Output ALU Block Diagram A-12 SMR Fail Alarm SSP EEPROM Detection D/I USART RS232 Communication WEB Communication SMR Current Limit Detection Temp.: 03 Figure 9: D/O A/D SMR Current (1-5) Load Current (1) Batt. Sensor Lock Off Breaker or Fuse Fail FL/EQU Exchange Signal Delta MCS-600 Power Shelf Customer Specification Confidential Installation.

Delta MCS-600 Power Shelf Installation. Operations and Maintenance Manual Figure 10: Schematics of MCS 600 Series System (-48) REV.: 03 A-13 Customer Specification Confidential .

CHUNGLI INDUSTRIAL ZONE. TEL : 886-2-87972088 FAX : 886-2-87972120 CHUNGLI PLANT 3 TUNG YUAN ROAD.O. R. CHUNGLI. NEIHU.TAIPEI OFFICE 186 RUEY KUANG ROAD.C. TAOYUAN HSIEN 320. TAIPEI 114. R.C. TAIWAN. 886-3-4527314 P/N:5011351000 .O. TEL. 886-3-4526107 FAX. TAIWAN.