SynQor MPS-4000 Series Manual

MPS-4000-1U
MPPS-4000-1U
1.888.567.9596 (USA only) |SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |www.synqor.com
Made in USA
Military Field-Grade Power SuPPly
Operator’s Guide
MPS-4000 Series &
MPPS-4000 Series

006-0006715 10/31/18 Rev J 2 of 44 MPS-MPPS-4000 Guide 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: MPS.............................................................................................................................................7
Product Topology: MPPS ..........................................................................................................................................8
Part Numbering Scheme and Options: MPS.....................................................................................................9
Part Numbering Scheme and Options: MPPS ............................................................................................... 10
Product Specifications............................................................................................................................................ 11
Technical Specifications: MPS ............................................................................................................................ 12
Technical Specifications: MPPS.......................................................................................................................... 13
Programmable Features: MPPS.......................................................................................................................... 13
Technical Specifications: MPS & MPPS........................................................................................................... 14
1U Mechanical Diagram....................................................................................................................................... 15
Efficiency: MPS.......................................................................................................................................................... 16
Total Output Power: MPS...................................................................................................................................... 17
Efficiency: MPPS....................................................................................................................................................... 18
Total Output Power: MPPS ................................................................................................................................... 19
Temperature Derating............................................................................................................................................ 20
MPS Droop Characteristics - All Ouput Voltages ........................................................................................ 21
MPPS Overload Characteristics ........................................................................................................................ 22
Power Cable Wiring Diagram ............................................................................................................................. 23

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Section III Operation
Set-Up ........................................................................................................................................................................... 24
Start-Up ....................................................................................................................................................................... 24
Shut-Down .................................................................................................................................................................. 24
Power Cable Connections...................................................................................................................................... 25
Programming The Output: MPPS Only........................................................................................................... 26
Programming the Output From the Web Interface............................................................................. 26
Programming the Output From the RS-232 Interface ....................................................................... 27
Cooling System .......................................................................................................................................................... 28
Front Panel Indicators ........................................................................................................................................... 29
Operating Environment......................................................................................................................................... 33
Section IV 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
Synchronized Operation of Multiple Units: MPS.......................................................................................... 38
Turn-On, Turn-Off, Restart Control:......................................................................................................... 38
Fault Synchronization Control:................................................................................................................... 38
Parallel Operation of Multiple Units: MPPS.................................................................................................. 39
Turn-On, Turn-Off, Restart Control:......................................................................................................... 39
Parallel Operation, Current sharing:........................................................................................................ 39
Section V Maintenance
Fans ............................................................................................................................................................................... 40
Cleaning....................................................................................................................................................................... 40
Section VI Trouble-Shooting Guide
Fault Conditions ....................................................................................................................................................... 41

Section I Warnings
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Section I Warnings
Hazardous Voltages
The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPS/MPPS 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 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
connector, even if the MPS/MPPS appears to be o.
▪Do not make contact with the terminals of the AC input connector.
▪Always connect the cable to the MPS/MPPS before it is connected to the source of AC power.
▪ Always disconnect the AC input cable from the source of AC power before disconnecng
it from the MPS/MPPS.
▪If the AC input cable is connected to the source of AC power and not connected to the
MPS/MPPS, do not contact the exposed terminals of the AC input cable.
▪Do not assume that the source of AC power is not present.
▪ Connecons between the AC input cable and the source of AC power should not be accessible.
• For the MPPS DC OUTPUT cable and connector:
▪The DC output terminals of the MPPS may be hazardous, depending on the model and user
commanded voltage. Never assume the terminals of the DC output connector or the wires
of the DC output cable are safe to contact, even if the MPPS appears to be o.
▪The DC output terminals of the MPPS are isolated from the AC input with reinforced
safety insulation.
• For the MPS DC OUTPUT cable and connector:
▪The rated DC output voltage of the MPS is below the level considered hazardous.
▪ The DC output terminals of the MPS 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
output cable are safe to contact, even if the MPS appears to be o.

Section I Warnings
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Hazardous Energies
The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPS/MPPS 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 MPS/MPPS Unit’s chassis or ground. DAMAGING ELECTRICAL ARCS
may result. Care should be taken to avoid accidental electrical contacts of this sort.
Protecon from the Environment
The SynQor MPS/MPPS is a ruggedly built product having its electronics contained in a sealed
chamber. It is capable of withstanding harsh levels of mechanical acceleraon, shock and
vibraon, temperature and pressure variaons, and exposure to water, salt, sand and dust
within the levels specied in the data sheet. THESE LEVELS SHOULD NOT BE EXCEEDED.
Do not obstruct the air intake in the front of the MPS/MPPS or the fan exhausts in the rear
panel of the MPS/MPPS while the MPS/MPPS is operang.
User Serviceable Parts
MPS/MPPS-4000 fans are user replaceable with kits available from SynQor. Please contact the
SynQor factory for obtaining fan replacement kits and instrucons (Replaceable Fan Module
SYN-9450). The SynQor MPS/MPPS has no other user serviceable parts inside of it. DO NOT
REMOVE the cover of the MPS/MPPS or any of its connectors. Other than fan assembly
replacement, only factory trained personnel should perform repairs.

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Section II General Product Information
Product Descripon
SynQor’s Military AC-DC Power Supply Units are designed for the extreme environmental and
demanding electrical condions of Military/Aerospace applicaons. SynQor’s MPS and MPPS
incorporate eld proven high eciency designs and rugged packaging technologies. The MPS
and MPPS will accept a 3-Phase input with a wide range of input voltage and frequency values
while delivering a well‑condioned connuous 4000 W, xed DC output to the load. It is designed
and manufactured in SynQor’s USA facilies to comply with a wide range of military standards.
A communicaon/control port is available to permit monitoring and control by a host computer
system. Front panel LEDs provide informaon on the status of the MPS. For MPPS Units, the
communicaon port allows the user to set the output voltage, and output current.
The electronic circuitry within the MPS‑4000 and MPPS‑4000 Series products is designed, qualied
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
specicaons for world‑wide commercial ulity applicaons.
The MPS-4000 and MPPS-4000 Series products are designed and manufactured to withstand
the harsh environments and use encountered in military applicaons. The electronic circuitry is
contained in a sealed chamber constructed from a die-cast aluminum chassis that is weather-proof
and shock‑proof. Redundant, water‑proof fans on the rear panel draw cooling air over the heat‑
sink ns below the sealed chamber. Military‑grade circular connectors are used, and oponal
aached connector covers are available for when the cables are not aached. The MPS‑4000
and MPP‑4000 Series products comply with a wide range of tesng according to MIL‑STD‑810G.
The SynQor MPS-4000 Series and MPPS-4000 Series products are designed and manufactured
in the U.S.A.

Section II General Product Information
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Product Topology: MPS
The SynQor MPS‑4000 Series products use an isolated topology that provides protecon to
the load from spikes, noise, surges, brownouts, blackouts, etc. in the input power sources.
They also provide smoothing of load transients and nonlinear load proles so that the input
power source is not subjected to these disturbances.
EMI lters are present at all external inputs and outputs
AC
INPUT
MAIN
DC
OUTPUT
AC to DC
w/ PFC
and
ISOLATION
OUTPUT
FILTERING
OUTPUT
CAPACITOR
INTERFACE
CONTROL
Power ows from the AC INPUT through an AC‑DC converter that has Power Factor Correcon
(PFC) and high‑frequency safety isolaon.
The DC outputs at various voltage and power levels are available. The DC can deliver up to
4000 W (5250 W transient) output.
Bulk energy storage capacitors are connected to the mid-bus to help smooth imbalances in
power ow between the inputs and outputs of the MPS.
There is a communicaon/control port that provides a digital interface to a host computer system.

Section II General Product Information
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Product Topology: MPPS
Similar to the MPS-4000, the MPPS-4000 Series products use an isolated topology that
provides protecon to the load from spikes, noise, surges, brownouts, blackouts, etc. in the
input power sources. They also provide smoothing of load transients and nonlinear load
proles so that the input power source is not subjected to these disturbances. The MPPS
adds an extra regulaon stage to the output, which allows the user to adjust the output
voltage and current.
EMI lters are present at all external inputs and outputs.
AC
INPUT
MAIN
DC
OUTPUT
AC to DC
w/ PFC
and
ISOLATION
DC-DC
w/ Digitally
Controlled
Vset, Imax
OUTPUT
FILTERING
Ideal
Diode
INTERFACE
CONTROL
Power ows from the AC INPUT through an AC‑DC converter that has Power Factor Correcon
(PFC) and high‑frequency safety isolaon.
The DC outputs at various voltage and power levels are available. The DC output voltage,
and maximum output current can be programmed by the user. The DC output can deliver
up to 4000W.
Bulk energy storage capacitors are connected to the mid-bus to help smooth imbalances in
power ow between the inputs and outputs of the MPPS.
An ideal diode on the output of the MPPS prevents circulang currents when Units are placed
in parallel. The ideal diode also provides some degree of redundancy should one MPPS in a
paralleled system experience a failure.
There is a communicaon/control port that provides a digital interface to a host computer
system. This port is used to program the output voltage and output current.

Section II General Product Information
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Part Numbering Scheme and Opons: MPS
This table shows the part numbering scheme for the full line of SynQor MPS products:
Family Output
Power Height AC Input Phase #
AC Input
Frequency
DC Output
Voltage
Range
Output Regulation Network
MPS 4000: 4000 W 1U: 1.73” 3: 3 Phase W: 47-800 Hz
2D: 28 V
2E: 30 V
4B: 48 V
S00: Semi-regulated E00: Ethernet/SNMP
For valid part numbers, refer to the website or contact your local sales representative.
Part Numbering Example: MPS-4000-1U-3W2ES00-E00
The MPS‑4000 Series of products provide up to 4000 W (5250W transient) of total output power.
Opons that can be specied according to the part numbering scheme shown in the table include:
• The allowable frequency of the AC INPUT can be in the 47‑800 Hz range.
• The nominal output voltage of the MPS‑4000 Series can be 28 V, 30 V, or 48 V.
• The DC OUTPUT is semi-regulated, meaning that the voltage droops slightly as the output
current increases. This facilitates current sharing when Mulple Units are connected in parallel.
• RS232 serial port and logic‑level I/O communicaon are included in the standard model. An
Ethernet port providing web and SNMP interfaces is standard.
Transit Case Option

Section II General Product Information
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Part Numbering Scheme and Opons: MPPS
This table shows the part numbering scheme for the full line of SynQor MPS products:
Family Output
Power Height AC Input Phase #
AC Input
Frequency
DC Output
Voltage
Range
Output Current
Range Network
MPPS 4000: 4000W 1U: 1.73” 3: 3 Phase W: 47-800Hz
28: 0-35V
48: 0-55V
72: 0-80V
150: 0-150A
120: 0-120A
078: 0-78A
E00: Ethernet/SNMP
For valid part numbers, refer to the website or contact your local sales representative.
Part Numbering Example: MPPS-4000-1U-3W28-150-E00
The MPPS‑4000 Series of products provide up to 4000 W of fully regulated DC output power.
Various opons can be specied according to the part numbering scheme shown in the table:
• The allowable frequency of the AC INPUT can be in the 47‑800 Hz range.
• The default output voltage of the MPPS‑4000 Series can be 28 V, 48 V, or 72 V. These models
are capable of 150A, 120A, and 78A maximum current respecvely.
• The DC OUTPUT is fully regulated.
• When placed in parallel, Units use a communicaon cable to ensure they are sharing evenly.
Each Unit will share to within +/- 3A of the average current at full load. All Units must have
the same output voltage programmed in order to share current evenly.
• RS232 serial port and logic‑level I/O communicaon are included in the standard model.
An Ethernet port providing web and SNMP interfaces is standard. The output voltage and
current can be set via the RS‑232 or web interfaces.

Section II General Product Information
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Product Specicaons
The following three pages show the electrical and mechanical specicaons of the MPS‑4000‑1U
& MPPS‑4000‑1U Series of products. Data sheets showing these specicaons and other
informaon can be found at the web site http://www.synqor.com/MPS.
MPS-4000-1U Unit or MPPS-4000-1U Unit Front Panel
On/Off Switch
DC
Output
Ethernet
Port
Fan
Exhaust
User
I/O
CONFIG
Port
Ground
Stud
(1/4-20)
AC
Input
Fan
Exhaust
Circuit
Breaker
Status Indication Panel
1.73"
1U
17.00"
Air intake
MPS-4000-1U Unit or MPPS-4000 1U Unit Rear Panel Rear Panel

Section II General Product Information
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Technical Specicaons: MPS
MPS INPUT CHARACTERISTICS
Operating AC Input
Voltage 3-Phase, 80-265 VrmsL-L*
Frequency 47-800 Hz
Input Power Factor >0.98 at 47-65 Hz
>0.97 at 400 Hz
>0.92 at 800 Hz
Maximum Input Current 27 Arms
May be programmed to less
via communications port
AC Input Circuit Breaker Rating 30 Arms
*PowerDerangvs.VrmsL-L(seeFigure2)
MPS OUTPUT CHARACTERISTICS
Total Output Power
Continuous 4000 W
15 s Transient 5250 W
Nominal DC Output Voltage at No Load
28 Vout 29.7 V
30 Vout 32.2 V
48 Vout 51.5 V
DC Output Voltage over Line, Load & Temperature
(Semi-regulated, see Figures 3-5)
28 Vout 30.3-27.6 V
30 Vout 32.8-29.9 V
48 Vout 52.5-47.9 V
Maximum Output Capacitance
28 Vout 255 mF
30 Vout 222 mF
48 Vout 86.8 mF
Output Ripple Voltage (20MHz BW)
All Output Voltages 0.5% peak-to-peak of rated Vout
Hold-up Time
To -20% rated Vout, 4000 W 10 ms
Turn-on Delay
All Output Voltages 2 s max.
Output Voltage Response to Load Transient
Iout steps from 50-75% 3% typ. / 6% max. deviation
at 0.2 A/μs 100 ms recovery
Over-voltage Protection
Cyclic Restart 110-120% rated Vout
Short Circuit Protection
Cyclic Operation 115% rated Iout

Section II General Product Information
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MPPS OUTPUT CHARACTERISTICS
Total Output Power Continuous 4000 W
Output Ripple Voltage (20MHz BW)
28 V Default (MPPS-4000-3W28) 25 mV max.
48 V Default (MPPS-4000-3W48) 38 mV max.
72 V Default (MPPS-4000-3W72) 50 mV max.
Current Limit Inception
All Models 110%-120% Current Set point
Hold-up Time
To -20% rated Vout, 4000 W 10 ms
Turn-on Delay
All Output Voltages 2 s max.
Output Voltage Response to Load Transient
Iout steps from 50-75% at 0.2 A/μs
28 V Default (MPPS-4000-3W28) 1 V max
48 V Default (MPPS-4000-3W48) 1.5 V max
72 V Default (MPPS-4000-3W72) 2 V max.
Short Circuit Protection
Constant current source 110-120% Current Set point
See Figure 4
MPPS INPUT CHARACTERISTICS
Operating AC Input
Voltage 3-Phase, 80-265 VrmsL-L*
Frequency 47-800 Hz
Input Power Factor >0.98 at 47-65Hz
>0.97 at 400Hz
>0.92 at 800Hz
Maximum Input Current Continuous 27 A
AC Input Circuit Breaker Rating 30 A
(Continuous full load, 110 VrmsL-L)
*Power Derating below 110 VrmsL-L (see Figure 2)
MPPS PROGRAMMABLE FEATURES
Model Part Number Programmable
Voltage Range
Programmable
Current Range
Voltage Set Point
Accuracy
Maximum Output Current
(Short Circuit)
28V Default
(MPPS-4000-3W28) 0 - 35 V 0 - 150 A ±5 mV typical ±25 mV max. 180 A
48V Default
(MPPS-4000-3W48) 0 - 55 V 0 - 120 A ±8 mV typical ±38 mV max. 145 A
72V Default
(MPPS-4000-3W72) 0 - 80 V 0 - 78 A ±10 mV typical ±50 mV max. 95 A
Technical Specicaons: MPPS
Programmable Features: MPPS

Section II General Product Information
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ENVIRONMENTAL CHARACTERISTICS MIL-STD-810G
Temperature Methods 501.5, 502.5
Operating Temperature
Full Rated Power -40 °C — +55 °C
Reduced Power per Figure 6 -40 °C — +70 °C
Storage Temperature -40 °C — +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
RELIABILITY CHARACTERISTICS MIL-HDBK-217F
MTBF 240 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 10 kHz - 40 GHz
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
Technical Specicaons: MPS & MPPS
MECHANICAL CHARACTERISTICS
1U Standard Battery Pack Chassis
Chassis Size 1.73”(1U)H x 17.00”W x 20.42”D
Case Material Aluminum
Total Weight 28 lbs
Connectors
AC Input Connector MS3470L18-8PW
DC Output Connector (+) CGE2E18H5FB-16
DC Output Connector (-) CGE2E18H5FWB-16
User I/O Ports HD DB15 Female
Conguration I/O Port HD DB15 Male
Ethernet Port Amphenol RJF22N00, Code B
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.

Section II General Product Information
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1U Mechanical Diagram
MPS
MADE IN USA
®
17.00"
[431.8]
20.42"
[518.6]
1.49" [37.8]
19.34"
[491.1]
.750"[19.05]
16.000"
[406.4]
.750"[19.05]
.750"[19.05]
.860"[21.84]
.313"[7.95] TYP.
UNIT
MOUNTING
HOLES
8-32 .250"
x24
1.73"[43.9]

Section II General Product Information
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Eciency: MPS
Figure 1 shows the typical eciency with which the MPS‑4000 series power supplies delivers
power to its DC OUTPUT from a 208 VrmsL-L AC INPUT and an 115 VrmsL-L AC INPUT:
65
70
75
80
85
90
95
100
01000 2000 3000 4000 5000
Efficiency (%)
Output Power (W)
208 Vrms L-L Continuous
208 Vrms L-L Transient
115 Vrms L-L Continuous
115 Vrms L-L Transient
Figure 1

Section II General Product Information
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Total Output Power: MPS
The total MPS output power for the MPS‑4000 series is rated at 4000 W (5250 W TRANSIENT)
for an ambient temperature as high as 55oC (131oF).
However, when the AC INPUT voltage is at the low end of its range (<100 VrmsL-L) or between
its low and high range (140 VrmsL-L ‑ 160 VrmsL-L) the MPS will not be able to deliver its full
rated output power in both the steady‑state and transient situaons. Fig. 2 indicates the total
steady‑state and transient output power that the MPS can deliver under these condions.
0
1000
2000
3000
4000
5000
6000
60 80 100 120 140 160 180 200 220 240 260 280
Output Power (Watts)
Input AC Voltage (V
rmsL-L
)
Transient 2s
Continuous
MIL-STD-1399
3ΦVoltage
Ranges Shown
Table III Transient
Table II Steady-state
Table III Transient
Table II Steady-state
MIL-STD-1399115VL-L MIL-STD-1399 200VL-L
Figure 2

Section II General Product Information
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Eciency: MPPS
Figure 3 shows the typical eciency with which the MPPS‑4000 series power supplies delivers
power to its DC OUTPUT from a 208 VrmsL-L AC INPUT and an 115 VrmsL-L AC INPUT. The extra
regulaon stage of the MPPS causes the eciency to be slightly lower when compared to an
MPS. Also note that there is no transient rang for the MPPS.
65
70
75
80
85
90
95
100
0 1000 2000 3000 4000
Efficiency (%)
Output Power (W)
208 Vrms L-L Continuous
115 Vrms L-L Continuous
Figure 3: Eciency vs Output Power

Section II General Product Information
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Total Output Power: MPPS
The total MPPS output power for the MPPS‑4000 series is rated at 4000 W for an ambient
temperature as high as 55oC (131oF).
However, when the AC INPUT voltage is at the low end of its range (<100 VrmsL-L) or between its
low and high range (140 VrmsL-L ‑ 160 VrmsL-L) the MPPS will not be able to deliver its full rated
output power in both the steady‑state and transient situaons. Figure 4 indicates the total
steady‑state and transient output power that the MPPS can deliver under these condions.
Unlike the MPS, the MPPS does not have a transient power rang. Exceeding 4000W under
any condion will cause the output voltage to fold back.
0
1000
2000
3000
4000
5000
60 80 100 120 140 160 180 200 220 240 260 280
Output Power (Watts)
Input AC Voltage (V
rmsL-L
)
Continuous
MIL-STD-1399
3ΦVoltage
Ranges Shown
Table III Transient
Table II Steady-state
Table III Transient
Table II Steady-state
MIL-STD-1399115VL-L MIL-STD-1399 200VL-L
Figure 4

Section II General Product Information
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Temperature Derang
The maximum steady‑state MPS or MPPS output power as a funcon of ambient air
temperature and AC input voltage is shown below in Figure 5.
0
500
1000
1500
2000
2500
3000
3500
4000
4500
40 45 50 55 60 65 70 75
DC Output Power (W)
Ambient Temperature (°C)
VAC > 105 Vrms L-L
VAC 105 to 95 Vrms L-L
VAC < 95 Vrms L-L
Figure 5: Output Power vs. Ambient Temperature