Delta MCS-600 Series Instruction manual

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

Delta MCS 600 Series
Power System
Installation, Operations &
Maintenance Manual
DELTA ELECTRONICS, INC.

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 INDEX-i Customer Specification Confidential
Table of Contents
1. General ---------------------------------------------- 1-1
1.1 Using This Manual ---------------------------------------------- 1-1
1.2 Safety Notice ---------------------------------------------- 1-1
2. Product Description ---------------------------------------------- 2-1
2.1 Product Description ---------------------------------------------- 2-1
2.2 Product Main Features ---------------------------------------------- 2-1
2.3 System Specifications ---------------------------------------------- 2-1
3. Power Supply Unit (PSU) ---------------------------------------------- 3-1
3.1 Description ---------------------------------------------- 3-1
3.2 Specifications ---------------------------------------------- 3-1
3.3 Operation and Adjustment ---------------------------------------------- 3-4
3.4 System Alarm ---------------------------------------------- 3-5
3.5 PSU Block Diagram ---------------------------------------------- 3-5
3.6 PSU Operating Principle ---------------------------------------------- 3-5
4. Alarm Control Unit ---------------------------------------------- 4-1
4.1 Description ---------------------------------------------- 4-1
4.2 Specifications ---------------------------------------------- 4-1
5. DC Distribution ---------------------------------------------- 5-1
5.1 DC Cabling ---------------------------------------------- 5-1
5.2 Low Voltage Battery Disconnect ---------------------------------------------- 5-1
5.3 Battery Connections ---------------------------------------------- 5-1
5.4 Battery Temperature Probe ---------------------------------------------- 5-1
6. Installation ---------------------------------------------- 6-1
6.1 Preliminary Inspection ---------------------------------------------- 6-1
6.2 System Mounting ---------------------------------------------- 6-1
6.3 Module Installation ---------------------------------------------- 6-1
6.4 Shelf Wiring ---------------------------------------------- 6-1
6.5 AC Input Connections ---------------------------------------------- 6-1
6.6 Battery String Connections ---------------------------------------------- 6-1
6.7 Temperature and Alarm Connections ---------------------------------------------- 6-2

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 INDEX-ii Customer Specification Confidential
Table of Contents
6.8 EXT. Breaker trip signal I/P Connector Wiring ---------------------------------------------- 6-2
6.9 AC High Voltage Aux. Relay Output Wiring ---------------------------------------------- 6-2
7. System Start –Up Procedure ---------------------------------------------- 7-1
7.1 Initial Start-Up Preparation ---------------------------------------------- 7-1
7.3 Basic Functional Verification 7.2 No Load
Start-Up ---------------------------------------------- 7-1
7.4 DC Load Connections ---------------------------------------------- 7-1
7.5 System Functionality Check ---------------------------------------------- 7-1
7.6 System Operation ---------------------------------------------- 7-1
8. System Alarms and Troubleshooting ---------------------------------------------- 8-1
8.1 AC Fail Voltage Alarm Description ---------------------------------------------- 8-1
8.2 High Voltage Shutdown Alarm ---------------------------------------------- 8-1
8.3 High Voltage Alarm Description ---------------------------------------------- 8-1
8.4 Low Voltage Alarm ---------------------------------------------- 8-2
8.5 Low Voltage Disconnect Alarm ---------------------------------------------- 8-2
8.6 Fuse Fail Alarm ---------------------------------------------- 8-2
8.7 Alarm Unit Fail ---------------------------------------------- 8-3
8.8 Rectifier Fail Alarm ---------------------------------------------- 8-3
9. Maintenance ---------------------------------------------- 9-1
9.1 Cleaning and Maintenance ---------------------------------------------- 9-1
9.2 Removing and Replacing a Rectifier Unit ---------------------------------------------- 9-1
10. Acronyms and Abbreviations ---------------------------------------------- 10-1
A ~ J ---------------------------------------------- 10-1
K ~ S ---------------------------------------------- 10-2
T ~ Z ---------------------------------------------- 10-3
Attachment List ---------------------------------------------- ATT
Figure 1: Functional Blocks Power Shelf ---------------------------------------------- A-1
Figure 1-1: Functional Blocks Power Shelf ---------------------------------------------- A-2
Figure 2: Control Supervisory Unit ---------------------------------------------- A-3
Figure 2-1: Control Supervisory Unit ---------------------------------------------- A-4
Figure 3: Switching Mode Rectifier ---------------------------------------------- A-5

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 INDEX-iii Customer Specification Confidential
Table of Contents
Figure 4: Breaker Position ---------------------------------------------- A-6
Figure 5: Battery and Load Cable Connection Terminal ---------------------------------------------- A-7
Figure 5-1: ---------------------------------------------- A-8
Figure 6: Alarm Relay Output Position ---------------------------------------------- A-9
Figure 7: Power Shelf Rear View ---------------------------------------------- A-10
Figure 8: PSU Block Diagram ---------------------------------------------- A-11
Figure 9: ALU Block Diagram ---------------------------------------------- A-12
Figure 10: Schematics of ES-600 Series System (-48V) ---------------------------------------------- A-13

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

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 2-1 Customer Specification Confidential
2 Product Description
2.1 Product Description
This power Shelf consists of modular rectifiers, an Alarm Control Unit (ALU), and a DC distribution module.
Up to five rectifiers and an alarm unit can be equipped on a shelf containing an integrated distribution module.
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. 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 –54.3 VDC at 10 Amps (HL)/5
Amps (LL), to power the load and maintain battery charge.
The system is controlled and monitored by the ALU. System level rectifier voltage settings, system status, and
alarms are displayed on the ALU. The system float voltage, equalize voltage, and alarm thresholds are set from
RMS or Web browser. The ALU also provides automatic derating of the output power over the whole
operating line voltages. Figure 1 shows different functional blocks of the system.
2.2 Product Main Features
The Power Shelf has the following main features:
 -48 VDC/50 Amps, N+1 redundancy (19” rack, 5 rack space mounting)
 Modular design for scalable, cost effective expansion
 Front access for simple installation and maintenance
 High power density
 Active Power Factor Correction (>.99PFC)
 High efficiency
 Temperature compensated float voltage control
 Alarm Control Unit
 Low Voltage Battery Disconnect (LVBD)
 Remote Monitoring and control
2.3 System Specifications
The system specifications are provided in the following sections.
2.3.1 -48V Standard Power Shelf Configuration
(1) AC Input: 175VAC ~ 275VAC, 20Amps. Max
(2) System Capacity: 50Amps. Max.
(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.
2.3.2 -48V System with Power Distribution and Rectifiers
(1) AC Input: 175VAC ~ 275VAC, 16Amps. Max
(2) System Capacity: 40Amps. Max.
(3) Rectifier: -48V/10A×1~4
(4) Control and Supervisory

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 2-2 Customer Specification Confidential
(5) Load Distribution: 10A Breaker×4 @ Single Pole
(6) Low Voltage Disconnect Switch: 100A×1 @ Single Pole at Battery Side
(7) Battery Breaker: 100A×1
Figure 1-1 shows a front view of shelf.
2.3.3 Electrical Data
The system electrical data is provided in the following tables.
2.3.3.1 Input
Table 1 displays the system input specifications.
Table 1 System Input Specifications
Specification Value
Nominal range 90-275 VAC
Operational range 175-275 VAC
Frequency 45-65 Hz
Power Factor >0.99
THD <5%
Efficiency >90%
2.3.3.2 Output
Table 2 displays the system output specifications.
Table 2 System Output Specifications
Specification Value
DC Volts 40-60 VDC
Power
Each module, HL
Each module, LL
System, HL
System, LL
600W
300W
3Kw
1.5Kw
Load regulation <0.5%
Line regulation <0.1%
Current Limit 110%
Current share <5%
Noise:
Audio band
Wide band
Acoustic
<2mv
<10 mVrms
<55 dBA
Battery breakers 1, 50 Amps CB
Temperature Compensation 50 to 100 mV/string

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 2-3 Customer Specification Confidential
2.3.3.3 Status/Alarm Indicators
The Power Shelf has the following status/alarm indicators:
 Load Current, % 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)
2.3.3.4 Mechanical Data
Table 3 displays the system mechanical data.
Table 3 System Mechanical Data
Dimension Value
Height 5.22 in. (132.6mm)
Depth 12 in. (304.4mm)
Width 19 in. (483mm)
2.3.3.5 Environmental Data
Table 4 displays the system environmental data.
Table 4 System Environmental Data
Specification Value
Operating temperature -0℃to +50℃
-20℃to +65℃OPTION
Storage temperature -40℃to +85℃
Humidity 0% to 95% RH
Altitude -300 ft. to 10,000 ft.
Weight Approximately 48 lbs.
EMI/FRI FCC Part 15, Class B and CISPR 22, Class B
Lightning/surge ANSI/IEEE C62.41-1, and IEC 1000-4-5
Seismic Bellcore GR-63-CORE, Zone 4
Safety CUL and UL Listed and CE Marked

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 3-1 Customer Specification Confidential
3 Power Supply Unit (PSU)
3.1 Description
This rectifier units are rated at 10 Amps at –48 VDC when operated from high line. For Low operation, the
output is derated to 5 Amps. This derating is automatically activated from the Alarm Control Unit (ALU).
However, the rectifier can operate on a stand-alone basis, if this ALU is removed or nonfunctional.
Warning: In the absence of the ALU, the automatic derating of the rectifiers at Low Line is not effective.
Exceeding the 50% load limit at Low Line may damage the rectifiers.
The modular design provides the flexibility to configure and expand the system as the load demand increases.
Each rectifier unit is swappable with front access for ease of maintenance without system shutdown, providing
uninterrupted service.
The rectifier unit has an active power factor correction of greater than 0.99 for maximum AC utilization. Each
module is equipped with an AC switch located at the front of the module.
3.2 Specifications
Detailed rectifier specifications are provided in the following sections.
3.2.1 Electrical
Detailed electrical specifications for the rectifier are provided in this section.
3.2.1.1 Input
Table 5 displays the rectifier input specifications.
Table 5 Rectifier Input Specifications
Specification Value
Input Voltage 90 VAC to 275 VAC, Single Phase, (during 175 to 120 VAC
derated to 70% Load, during 120 to 90 VAC derated to 50%
Load)
Input Current 4 Amps at 176 VAC, Full Load
Line Frequency 45 to 65 Hz
Power Factor >0.99, at 220 VAC Input, Full Load
THD <5%, at 220 VAC Input, Full Load
Efficiency >90%, Full Load
Inrush Current <9 Amps (peak), 220 VAC, Full Load, Cold Start
Start Time Delay
(Walk-In) 3 to 10 seconds
Protection Fuse
3.2.1.2 Output
Table 6 displays the rectifier output specifications.
Table 6 Rectifier Output Specifications

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 3-2 Customer Specification Confidential
Specification Value
DC Output Voltage 40 to 60 VDC [factory preset at –54.3 VDC, 10
Amps (HL) / 5 Amps (LL)]
Output Power 600 W Maximum
Regulation:
Load
Line
<0.5% (Load 0 to 100%)
<0.1%
Current Limit 110% Max. of Rated Output Current
Noise:
Audio Band
Wide Band
Acoustic
<2mV
<10 mVrms (10 KHz to 100 MHz)
<55 dBA @ 1M
Current Sharing <5% of Rated Output Current
Dynamic Response 10% to 90% Load Change Overshoot ≤5% Rated
Output Voltage Recovery Time <1 ms to ≤1% Rated
Output Voltage
Protection Fuse
3.2.1.3 Protection
Table 7 displays the protection specifications.
Table 7 Protection Specifications
Condition Response
High Output Voltage (Exceeds
Preset Value) Automatic Shutdown and Latch
Over Current/Output Short Automatic Shutdown and Recovery
Over Temperature Automatic Shutdown and Recovery
Brownout No Damage
AC Input Voltage High Automatic Shutdown and Recovery
AC Input Voltage Low Automatic Shutdown and Recovery
3.2.1.4 Adjustments
Table 8 displays the adjustments.
Table 8 Adjustments
Adjustment Description
Test Points (I+,I-) Current
Float Voltage (FLO) Variable Resistor or Setting on ALU
Current Limit (CL) Variable Resistor or Setting on ALU

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 3-3 Customer Specification Confidential
3.2.2 Environmental
Table 9 displays the environmental specifications.
Table 9 Environmental Specifications
Specification Value
Operating temperature -4 to +149℉(-20℃to +65℃)
Storage temperature -40 to +185℉
(-40℃to +85℃)
Humidity 0% to 95% Relative Humidity Noncondensing
Altitude -500 ft. to 10,000 ft.
Weight 2 Kg (4.4 lbs.)
EMI/FRI suppression Conforms to EN 55022, BS 6527 FCC Part 15
Subpart J, and CISPR 22 Class B
Current harmonic Conforms to EN 61000-3-2/A12, EN 60555-2, IEC
555-2 Class A
Voltage fluctuation Conforms to EN 61000-3-3, EN 60555-3
Electrostatic discharge Conforms to EN 61000-4-2, IEC 1000-4-2, IEC
801-2 Level 4
Radiated susceptibility Conforms to IEC 1000-4-3, IEC 801-3 Level 3
Electrical fast transients Conforms to EN 61000-4-4, IEC 1000-4-4, IEC
801-4 Level 4
Conducted susceptibility Conforms to IEC 1000-4-6 Level 3
Lightning/surge Conforms to ANS/IEEE C62.41.-1, 1991 B3, IEC
1000-4-5 Level Special (6KV)
Safety Meets IEC 950, EN60950, UL/CUL and UL Listed
and CE Marked
MTBF >150 K hours
Cooling Fan cooling
Heat dissipation 228 BTU/hour max. per module
3.2.3 Status/Alarm Indicators
Table 10 displays the status alarm indicators
Table 10 Status Alarm Indicators
Indicator Color Function Description
LED Amber CL Current Limit
LED Green AC AC ON
LED Red RFA Rectifier Failure Alarm
3.2.4 Mechanical Data

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 3-4 Customer Specification Confidential
Table 11 displays the rectifier mechanical data.
Table 11 Rectifier Mechanical Data
Dimension Value
Height 5.2 in. (132mm)
Depth 9.57 in. (243.1mm)
Width 2.5 in. (63.6mm)
3.3 Operation and Adjustment
All operating adjustments are made at the front panel of each rectifier. The following components are located
on each rectifier panel:
1. Float voltage adjustment
2. Current limit adjustment
3. Current test points
4. Alarm indicators
Figure 3 shows different indicators and adjustment points on this unit.
Rectifier adjustments must be done sequentially from the first through the fourth rectifier with AC applied. All
adjustments must be made with no load, and the batteries disconnected to ensure adjustment accuracy.
3.3.1 Start-Up
To start up the system, perform the following steps:
1. Aproximately 3 to 8 seconds after the AC applied, the RFA LED extinguishes.
3.3.2 Float Voltage Adjustment
Verify the required float voltage setting per battery manufacturer specification. If the factory setting differs
from the battery manufacturer recommended setting, the ALU float voltage parameter and each rectifier’s
float voltage must be adjusted to the new setting. A digital multimeter and a small screwdriver are required
to perform this procedure. Located the float voltage access point (FL) at the front of the rectifier.
To adjust the float voltage, perform the following steps:
1. Remove the ALU.
2. Place the digital multimeter probe in the V+ and V- output voltage connecter.
3. Adjust the float voltage by using a screwdriver to turn the FL point to the voltage value as shown on
the meter. The tolerance error should not exceed 0.02V.
Notes:
1. Turning the variable resistor adjustment point clockwise increases the value, and counterclockwise
2. Refer to attachment 7-1 and 7-2 (rectifier front view) for the location of V+, V- and FL point.
3. When the setting is completed, temperature and voltage compensation must be reset to the default
value.
3.3.3 Current Limit Setting
Warning: Current limit setting is not intended to be adjusted in the field. Users should only use it for their
reference.

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 3-5 Customer Specification Confidential
Current limit adjustment is made by turning the CL variable resistor with the digital multimeter
probes in the I+, I- test points. This current limit is set at the factory. The factory setting is
always the maximum value of 110%. For a 10-Amp rectifier, the computation for the current limit
is 1.1×10=11 Amps.
The following adjustment procedure is for reference only:
1. At the rectifier, place the digital multimeter probes in the I+, I- test points.
2. Place a small screwdriver in the CL adjustment point.
3. Turn the variable resistor counterclockwise to increase the value. Turn the variable
resistor clockwise to decrease the current limit value.
3.4 System Alarm
During an alarm condition, the faulty rectifier illuminates its RFA light on the front panel. The rectifier fail
alarm signal is sent to the ALU, which processes the alarm, closes the RFA alarm contacts, and lights the alarm
LEDs.
3.5 PSU Block Diagram
Refer to Figure 8.
3.6 PSU Operating Principle
After applying the incoming line voltage to the rectifier, current is applied to the EMI filter and circulates
through protection components such as the AC circuit breaker and the fuse. The major functions of the
protection devices are to prevent the rectifier from being damaged by surge voltage, to efficiently reduce the
noise of differential mode and common mode, to eliminate the high frequency noise from input current, and to
prevent noise reverse to the source circuit.
The AC input voltage is rectified and converted to a 400 VDC bus through a PFC boost stage. This PFC stage
maintains the Power Factor at >.99 and the Total Harmonic Distortion (THD) at <5%.
The 400 VDC bus voltage is modulated at a frequency higher than 75 KHz and stepped down through a
transformer. Output of this transformer is rectified and filtered to provide the output DC voltage.

Delta MCS-600 Power Shelf
Installation, Operations and
Maintenance Manual
REV.: 03 4-1 Customer Specification Confidential
4 Alarm Control Unit
4.1 Description
The Alarm Control Unit (ALU) with RS232 & LAN interface and remote monitoring function provides
output alarms, alarm threshold adjustments, float and equalize voltage adjustments, temperature compensation
voltage settings, low voltage disconnect voltage threshold settings, an equalize charge timer, and system alarm
LEDs. In addition, the ALU automatically derates the system output current according to the following table:
Table 12 Voltage Ranges
Input Voltage Range Output
90-120 VAC 50%
121-175 VAC 70%
176-275 VAC 100%
The module is hot-swappable.
4.2 Specifications
4.2.1 Input Characteristics
Table 13 displays the input characteristics.
Table 13 Input Characteristics
Characteristic Value
Input Voltage Range 20V to 59.5V
Input Current <0.5 Amps
4.2.2 Push Buttons
This alarm unit has 3 push buttons on the front panel. These push buttons are used to control the alarm
unit. Following are possible functions these buttons will act:
Control
- FL/EQU
- HVSD RST
- SMR RST
Table 14 displays the Push Buttons
Settings Description

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