MPC DC Output Series Manual
SHALLOW RACK MOUNT!
Made in USA
Military Power Conditioner
MPC-1250-1S
Operator’s Guide
MPC‑1250
DC Output Series
006-0007207 MPC-1250DC Guide Rev F 2 of 44 03/03/2022 www.synqor.com
Table of Contents
Section I Warnings
Hazardous Voltages ...................................................................................................................................................4
Hazardous Energies...................................................................................................................................................5
Protection from the Environment .........................................................................................................................5
User Serviceable Parts...............................................................................................................................................5
Section II General Product Information
Product Description ...................................................................................................................................................6
Product Topology ........................................................................................................................................................7
Part Numbering Scheme and Options ................................................................................................................8
Electrical Characteristics ........................................................................................................................................9
Product Specifications............................................................................................................................................ 10
MPC-1250-1S 1U Mechanical Diagram.......................................................................................................... 11
MPC Efficiency.......................................................................................................................................................... 12
Total Output Power that can be derived from the AC INPUT ................................................................. 13
Power Cable Wiring Diagram ............................................................................................................................. 15
Power Cable Wire Size............................................................................................................................................ 16
Section III Operation
Set-Up ........................................................................................................................................................................... 18
Start-Up ....................................................................................................................................................................... 19
Shut-Down .................................................................................................................................................................. 19
Power Cable Connections/Disconnections While Operating .................................................................. 20
Cooling System .......................................................................................................................................................... 21
Front Panel Indicators ........................................................................................................................................... 22
LEDs...................................................................................................................................................................... 22
Audible alarm................................................................................................................................................... 25
Operating Environment......................................................................................................................................... 26
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Section IV Constant Current Model
Overview...................................................................................................................................................................... 27
User Settable Parameters – CCCV charging .................................................................................................. 27
Setting CCCV parameters ..................................................................................................................................... 28
Over Power and Over Current Protection....................................................................................................... 29
Entering and Exiting Charge Mode................................................................................................................... 30
Visual indicators - External Battery Charge Level.................................................................................... 30
Output Vampire Current – Unpowered............................................................................................................ 31
Reverse Polarity Protection .................................................................................................................................. 31
Section V Multiple MPC Configurations
Parallel Connection of DC OUTPUTS – Parallel Option........................................................................... 32
N+M Redundancy - Ideal Diode................................................................................................................ 32
Configuration Cables...................................................................................................................................... 33
On/Off control – Parallel Systems ............................................................................................................. 33
Section VI Control Interface Details
Control Cable Connections................................................................................................................................... 34
Internal User I/O Circuits............................................................................................................................. 35
Remote On/Off Switch Connections ......................................................................................................... 35
Digital Input/Output Control Signals............................................................................................................... 36
RS232 Serial Interface............................................................................................................................................ 36
Ethernet Interface.................................................................................................................................................... 37
Section VII Maintenance
Fans ............................................................................................................................................................................... 38
Cleaning....................................................................................................................................................................... 38
Section VIII Trouble-Shooting Guide
Fault Conditions ....................................................................................................................................................... 39
Section I Warnings
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Section I Warnings
Hazardous Voltages
The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPC may have
voltages that are unsafe. INJURY OR DEATH ON CONTACT may result. Appropriate safety
precautions should be taken. All connections should be made in accordance with LOCAL
ELECTRICAL CODES.
• The MPC CHASSIS should be connected to earth or system ground with Ground Stud on the
rear panel, see mechanical diagrams.
• For the AC INPUT cable and connector:
Do not assume that a hazardous voltage is not present at the terminals of the AC input
Do not make contact with the terminals of the AC input connector.
Always connect the cable to the MPC before it is connected to the source of AC power.
from the MPC.
If the AC input cable is connected to the source of AC power and not connected to the
MPC, do not contact the exposed terminals of the AC input cable.
Do not assume that the source of AC power is not present.
Connections between the AC input cable and the source of AC power should not be
accessible.
• For the DC INPUT cable and connector:
The rated DC input voltage of the MPC is below the level considered hazardous.
The DC input terminals of the MPC are isolated from the AC input with reinforced safety
However, never assume the terminals of the DC input connector or the wires of the DC
input cable are safe to contact, even if the MPC or DC input source appears to be o.
• For the DC OUTPUT cable and connector:
The rated DC output voltage of the MPC is below the level considered hazardous.
The DC output terminals of the MPC are isolated from the AC input with reinforced
safety insulation.
However, never assume the terminals of the DC output connector or the wires of the DC
Section I Warnings
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Hazardous Energies
The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPC may be the source
of high levels of energy. Do not inappropriately make electrical contact between any terminal of
a connector and another, or between any wire of a cable and another, or between any terminal
or wire and the MPC’s chassis or ground. DAMAGING ELECTRICAL ARCS may result. Care should
be taken to avoid accidental electrical contacts of this sort.
Protecon from the Environment
The SynQor MPC is a ruggedly built product having its electronics contained in sealed chambers.
THESE LEVELS SHOULD NOT BE EXCEEDED.
Do not obstruct the air intake in the front of the MPC or the fan exhausts in the rear panel of the
User Serviceable Parts
MPC‑1250 DC Output Series fans are user replaceable with kits available from SynQor. Please
Module SYN‑9450). The MPC‑1250 DC Output Series has no other user serviceable parts inside
of it. DO NOT REMOVE the cover of the unit or any of its connectors. Other than the fan assembly
replacement, only factory trained personnel should perform repairs.
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Section II General Product Information
Product Descripon
The MPC‑1250 DC Output Series products can draw power from an AC input having a wide range
of voltage and frequency levels, or from an 28 V nominal DC input. The AC input has priority over
the DC input. The MPC provides up to 1250 W of DC output power at 24 or 28 volts nominal.
and screened according to SynQor’s MIL‑COTS Standards. It complies with the requirements of
MIL‑STD‑704F, MIL‑STD‑1399‑300B, MIL‑STD‑1275D and MIL‑STD‑461F, as well as IEC‑EN61000
The MPC‑1250 DC Output Series products are designed and manufactured to withstand the harsh
a sealed chamber constructed from a die‑cast aluminum chassis that is weather‑proof and shock‑
The SynQor MPC‑1250 DC Output Series products are designed and manufactured in the U.S.A.
Section II General Product Information
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Product Topology
The SynQor MPC‑1250 DC Output Series products use a true on‑line double conversion topology
the input power sources. They also provide smoothing of load transients and nonlinear load
output voltage waveform.
AC
INPUT
DC
INPUT
DC
OUTPUT
AC to DC
w/ PFC
and
ISOLATION
ELECTRONIC
SWITCH
ISOLATED
DC-DC
CONVERTER
BULK ENERGY
STORAGE
CAPACITOR
IDEAL
DIODE
switch that is closed when the AC INPUT power is absent and the DC INPUT voltage is within
The DC output can deliver up to 1250 W. The DC output is isolated from the AC input.
Bulk energy storage capacitors are connected to the mid‑bus to help smooth imbalances in
Section II General Product Information
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Part Numbering Scheme and Opons
This table shows the part numbering scheme for the full line of SynQor MPC products:
Base Models
Model Number Power Height (W x D x H) Weight
MPC-1250-1S 1250 W 1U (17.00” x 14.80” x 1.73”) 22 lbs.
Base Model
Options Options
AC Input
Frequency
DC
Regulation
Type
DC
Output
Voltage
DC
Input
Additional
Options
AC Input
Freq
L47 - 65 Hz
W47 - 800 Hz
DC Reg
RFully Regulated, No Paralleling
MPC-1250-1S- L
W
R
P
C
28
24 D00 -E 00
CE
PFully Regulated with Paralleling
CConstant Current Overload Protection
DC Output 28 28 V Output *
24 24 V Output *
Not all combinations make valid part numbers, please contact SynQor for availability. DC Input D00 DC Input
See the Product Summary web page for more options.
Additional
Options
-E Ethernet/SNMP with Conguration Loading
00 No CE Marking
Examples: CE CE Marking
MPC-1250-1S-LR28D00-E00, MPC-1250-1S-WP24D00-E00, MPC-1250-1S-LR28D00-ECE (Fully Regulated with CE Marking)
* Select 28 V Output option when ordering Constant Current regulation type
• The output voltage of the MPC‑1250 DC Output Series can be 24 or 28 volts nominal.
28 V systems
Ethernet port provides web and SNMP interfaces.
Section II General Product Information
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Electrical Characteriscs
INPUT CHARACTERISTICS
Operating AC Input
Voltage 80 - 265 Vrms*
Frequency 47 - 65 Hz
(47 - 800 Hz Optional)
Input Power Factor >0.98 at 47 - 65 Hz
>0.97 at 400 Hz
>0.93 at 800 Hz
Maximum Input Current Continuous 20 A (full load, 85 Vrms)
AC Input Circuit Breaker Rating 25 A
(* Power Derating to 80 % below 90 Vrms)
Operating DC Input
Voltage 22-33 V
Continuous Maximum Input Current 62 A (full load, 22 V)
Transient Maximum Input Current 75 A
Reverse Polarity Protection -60 V
OUTPUT CHARACTERISTICS
Output Power Continuous 1250 W
Voltage Setpoint Accuracy ± 3 %
Voltage Regulation (Over Load & Temperature) ± 5 %
DC Output - Fully Regulated
28 V Option
Voltage Setpoint (Nominal) 28 V
Operating Output Current Range 0 - 45 A
Overload Current Maximum ( < 1 sec) 60 A
Reverse Polarity Protection None
24 V Option
Voltage Setpoint (Nominal) 24 V
Operating Output Current Range 0 - 52 A
Overload Current Maximum ( < 1 sec) 60 A
Reverse Polarity Protection None
DC Output - Constant Current
28 V Option
Voltage Setpoint (Nominal) 28 V
Operating Output Current Range 0 - 45 A
Overload Current (Continuous) 47 A
Output Vampire Current - Unpowered < 2 uA
Reverse Polarity Protection -60 V
RELIABILITY CHARACTERISTICS MIL-HDBK-217F
MTBF 100 kHrs MIL-217F Ground Benign, Ta=25 °C
ELECTROMAGNETIC CAPABILITY MIL-STD-461F
CE101** 30 Hz - 10 kHz
CE102 10 kHz - 10 MHz
CS101 30 Hz - 150 kHz
CS106 Pulse Transient
CS114 10 kHz - 200 MHz
CS116 10 kHz - 100 MHz
RE101 30 Hz - 100 kHz
RE102 10 kHz - 18 GHz
RS101 30 Hz - 100 kHz
RS103 2 MHz - 40 GHz
** Regarding MIL-STD-461 CE-101, the 50 uH series inductance of a standard LISN
adversely affects the input ripple of the MPC (DC input only). Such a large series
source inductance (50 uH in each power lead) is not generally encountered in a
28 V DC source of such high power rating. Therefore, testing for CE-101 (DC input)
was conducted with 3 different congurations: two using 50 uH LISNs and a 54 mF
capacitor connected across the input to the MPC, and one using 5 uH LISNs for
which no additional capacitor was added.
These congurations all passed CE-101 for all frequencies.
MECHANICAL CHARACTERISTICS
Chassis
Chassis Width 17.00 ”W
Chassis Depth 14.80 ”D
Chassis Height 1.73 “(1U)H
Case Material Aluminum
Total Weight 22 lbs.
Cooling Exhaust Fans
Sound Pressure Level (SPL) 54 dB(A)
Air Flow 0.67 (m3/min) 23.7 CFM
Two fans in system, above specs are for each fan separately.
MECHANICAL CONNECTORS
Connectors
AC Input Connector MS3470L14-4P
User I/O Ports HD DB15 Female
Conguration I/O Port HD DB15 Male
Ethernet Port Amphenol RJF22N00,
Code B
DC Input Connector MS3470L18-8P
DC Output Connector MS3470L18-8S
ENVIRONMENTAL CHARACTERISTICS MIL-STD-810G
Temperature Methods 501.5, 502.5
Operating Temperature -40 °C to 70 °C 1
Storage Temperature -40 °C to 70 °C
Altitude Method 500.5
Operating 0 - 18,000 ft
Non-operating 0 - 40,000 ft
Environmental Tests
Shock/Drop Method 516.6, Procedures 1,4,6
Temperature Shock Method 503.5, Procedure 1
Vibration Method 514.6, CAT 5, 7, 8, 9, 24
Fungus Method 508.6
Salt Fog Method 509.5
Sand and Dust Method 510.5, Procedures 1,2
Rain Method 506.5 Procedure 1
Humidity Method 507.5 Procedure 2
Mechanical Vibrations of Method 528 Procedure 1
Shipboard Equipment
1 100 % rated power at 55 °C, 0 % rated power at 70 °C.
Derate linearly.
Section II General Product Information
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Product Specicaons
at the web site. http://www.synqor.com/MPC
MPC-1250-1S with AC & DC Input / DC Output
MPC-1250-1S
MPC-1250-1S With Constant Current Output
On/Off
Switch
On/Off
Switch
DC
Output
Fan
Exhaust
DC
Input Fan
Exhaust
AC Circuit
Breaker
AC
Input
Status
LED
Status
LED
Status Indication Panel
Status Indication Panel
External Battery Voltage
1.73"
1U
17.00"
Air intake
User
I/O
Cong
Port
Ethernet
Port
Ground
Stud
(1/4-20)
Section II General Product Information
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MPC-1250-1S 1U Mechanical Diagram
MILITARY
POWER CONDITIONER
STATUS
MPC 1.73"
1.50"
17.00"
14.80"
14.00"
.750"
.750"
.750"
11.750"
0.55
"
0.313"
0.625"
Section II General Product Information
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MPC Eciency
power supplies delivers power to its DC OUTPUT from a 22, 28, and 33 volts input.
80
82
84
86
88
90
92
94
0 250 500 750 1000 1250
Efficiency (%)
Output Power (W)
Efficiency vs. Output Power
28 V
33 V
22 V
Figure 1
power supplies delivers power to its DC OUTPUT from 115 VAC and 230 VAC input.
70
72
74
76
78
80
82
84
86
0 250 500 750 1000 1250
Efficiency (%)
Output Power (W)
Efficiency vs. Output Power
115 Vac
230 Vac
Figure 2
Section II General Product Information
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Total Output Power that can be derived from the AC INPUT
The total MPC output power for the MPC‑1250 DC Output Series is rated at 1250 W for an
ambient temperature as high as 55oo
can derive
• If the AC INPUT voltage is above 105 Vrms, then the MPC can deliver its full rated output
power of 1250 W from the AC INPUT for an ambient temperature as high as 55o oF)
• If the AC INPUT is between 90 Vrms and 80 Vrmsthen the total output power that can be
derived from the AC INPUT linearly decreases from 1250 W at 90 Vrms to 1000 W at 80 Vrms
total output power that could be derived from the AC INPUT would be 1125 W at 85 Vrms as
long as the ambient temperature is not above 50ooF). If the total output power is greater
• If the AC INPUT voltage is 90 Vrms the ambient air temperature is above 45ooF),
the total output power that can be derived from the AC INPUT linearly decreases from 1250
W at 45ooF) to 1000 W at 55ooF). For example, the total output power that could
be derived from the AC INPUT would be 1125 W at an AC INPUT voltage of 90 Vrms and an
ambient temperature of 50ooF). A higher output power than this would cause the MPC
to switch over to its DC INPUT.
• When the AC INPUT voltage is between 105 Vrms and 90 Vrmsthe ambient temperature
is between 45oC and 55oC, the total output power that can be derived from the AC INPUT can
power that can be derived from the AC INPUT when the voltage is 97.5 Vrms would be 1250 W
up to an ambient temperature of 50ooF) and then derate to 1125 W at 55ooF).
and 160 Vrmsin which the total output power that can be derived from the AC INPUT is also
derated, as shown in Figure 3.
Section II General Product Information
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1100W
0
200
400
600
800
1000
1200
1400
60 80 100 120 140 160 180 200 220 240 260
280
Output Power (Was)
Input Voltage (Vrms)
Output Power vs. AC Input Voltage
(without switching over to the DC input)
132V Steady state
15s transient
2s transient
Figure 3
Note that the full rated output power of 1250 W can be derived from the AC INPUT having a voltage
within this uncommon range for 15 seconds before the MPC will switch over to the DC INPUT. Also note
that the MPC can drive it full rated power for a 2 second interval even if the AC INPUT voltage drops
below 90 Vrms.
0
200
400
600
800
1000
1200
1400
25 30 35 40 45 50 55
Air Temperature (°C)
MPC Output Power vs. Air Temperature
VAC(IN) >105 VRMS or VDC(IN) >22 V
VAC(IN) = 90 VRMS and VDC(IN) <22 V
VAC(IN) = 80 VRMS and VDC(IN)
<22 V
Output Power (Was)
Figure 4
Section II General Product Information
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Looking at the rear panel, the MPC connector terminals have the following functions and locations:
AC INPUT
B
C
Ground
A
B
D
C
DC INPUT
+V
V
A
B
C
D
E
F
G
H
DC OUTPUT
+V
V
A
HFC
B G
DE
Section II General Product Information
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Power Cable Wire Size
SynQor recommends the following cables for use with the MPC‑1250 DC Output Series:
info@synqor.com or visit the website:
http://www.synqor.com
Damage caused by improper wiring of cables will not be covered under SynQor’s warranty.
end of the cable to the other. In other words, the voltage across the cable at its downstream end
through the wire. It is therefore to make sure that the
enough to keep this voltage drop to an acceptably small value.
While this is an issue for all of the power cables,
though the voltage at the source of the DC power is greater than 22 V.
The resistance of a wire depends directly on its length. A wire twice as long as another will
have twice the resistance, holding all other things constant. The resistance also depends on
resistance, holding all other things constant.
Section II General Product Information
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Therefore, the longer a cable is, the more important it is that the wire’s diameter be large.
for the MPC‑1250 DC Output Series:
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Section III Operation
Set-Up
• Connect the ground wire to the ground stud on the rear panel of the MPC.
• that the DC OUTPUT cable is connected to the MPC and the load with the correct
polarity.
• An overcurrent protect and disconnect device should be installed on the DC INPUT
circuit. An example of a suitable device is a Carling Technologies, C‑series, 80 A 65 VDC,
• that the DC INPUT cable is connected to the MPC and the source of DC power with
the correct polarity.
MPC to turn on and present a hazardous voltage at its output.
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Section III Operation
Start-Up
•
is in standby mode and ready to turn on. The front panel LEDs will also be appropriately
illuminated.
panel will indicate the amount of power being delivered to the load and the input source
from which this power is being drawn.
Shut-Down
• Shut down the equipment connected to the MPC.
• The MPC will disable its output and shut down.
Section III Operation
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Power Cable Connecons/Disconnecons While Operang
that the input and output power cables be
connected to the MPC before the source of AC or DC input power is turned on, and before the
and the
are disconnected from the MPC.
However, the SynQor MPC is capable of having any of its input or output power cables connected
load. For instance:
• Even if the MPC is turned on, one can connect or disconnect the input power cables without
available, the MPC will shut down. When there is an external source of power connected
if present, and then the DC input source. The transfer from one source of power to another
is seamless.
• Even if the MPC is turned on, one can connect or disconnect an output power cable without
other output.
NOTE
cause an arc to form as the terminals are pulled apart. This arcing is not harmful to the MPC, although
.
ALSO NOTE that when the MPC is turned on and delivering power to a load, and then another piece of
the quality of the MPC’s output voltage. If the MPC is turned on and delivering power to several loads
and then another load is connected, it is possible that this new load will momentarily draw a large surge
of current as it starts up. If this happens, the output of the MPC could reach its maximum current limit,
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