Operator's Guide

MPS
Operator’s Guide
MPS-4000 Series
Military-Grade Power Supply
MPS-4000-1U
Made in USA
Advancing The Power Curve
1.888.567.9596 (USA only) | SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |
®
www.synqor.com
Table of Contents
Section I
Warnings
Hazardous Voltages....................................................................................................................................................4
Hazardous Energies....................................................................................................................................................4
Protection from the Environment..........................................................................................................................5
No User Serviceable Parts.........................................................................................................................................5
Section II
General Product Information
Product Description....................................................................................................................................................6
Product Topology.........................................................................................................................................................7
Part Numbering Scheme and Options.................................................................................................................8
Product Specifications...............................................................................................................................................9
Technical Specifications......................................................................................................................................... 10
1U Mechanical Diagram........................................................................................................................................ 11
MPS Efficiency............................................................................................................................................................ 12
Total Output Power that can be derived from the AC INPUT.................................................................. 12
Droop Characteristics - All Ouput Voltages.................................................................................................... 14
Power Cable Wiring Diagram.............................................................................................................................. 15
Warranty...................................................................................................................................................................... 16
Section III
Operation
Set-Up............................................................................................................................................................................ 18
Start-Up........................................................................................................................................................................ 18
Shut-Down................................................................................................................................................................... 19
Power Cable Connections...................................................................................................................................... 19
Cooling System........................................................................................................................................................... 20
Front Panel Indicators............................................................................................................................................ 21
Operating Environment.......................................................................................................................................... 25
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Section IV
Control Interface Details
Control Cable Connections.................................................................................................................................... 26
Internal User I/O Circuits.............................................................................................................................. 27
Remote On/Off Switch Connections.......................................................................................................... 27
Digital Input/Output Control Signals................................................................................................................ 28
RS232 Serial Interface............................................................................................................................................. 29
Ethernet Interface..................................................................................................................................................... 30
Synchronized Operation of Multiple Units...................................................................................................... 31
Turn-On, Turn-Off, Restart Control:.......................................................................................................... 31
Fault Synchronization Control:.................................................................................................................... 31
Section V
Maintenance
Fans................................................................................................................................................................................ 32
Cleaning........................................................................................................................................................................ 32
Section VI
Trouble-Shooting Guide
Fault Conditions........................................................................................................................................................ 33
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Section I
Warnings
Hazardous Voltages
The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPS 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 MPS 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 appears to be off.
▪ Do not make contact with the terminals of the AC input connector.
▪ Always connect the cable to the MPS before it is connected to the source of AC power.
▪ Always disconnect the AC input cable from the source of AC power before disconnecting
it from the MPS.
▪ If the AC input cable is connected to the source of AC power and not connected to the
MPS, 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 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 off.
Hazardous Energies
The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPS 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’s chassis or ground. DAMAGING ELECTRICAL ARCS may result.
Care should be taken to avoid accidental electrical contacts of this sort.
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Section I
Warnings
Protection from the Environment
The SynQor MPS is a ruggedly built product having its electronics contained in a sealed
chamber. It is capable of withstanding harsh levels of mechanical acceleration, shock and
vibration, temperature and pressure variations, and exposure to water, salt, sand and dust
within the levels specified in the data sheet. THESE LEVELS SHOULD NOT BE EXCEEDED.
Do not obstruct the air intake in the front of the MPS or the fan exhausts in the rear panel of
the MPS while the MPS is operating.
No User Serviceable Parts
The SynQor MPS has no user serviceable parts inside of it. DO NOT REMOVE the cover of the
MPS or any of its connectors. Only factory trained personnel should perform repairs.
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Section II
General Product Information
Product Description
SynQor’s Military AC-DC Power Supply units are designed for the extreme environmental
and demanding electrical conditions of Military/Aerospace applications. SynQor’s MPS
incorporates field proven high efficiency designs and rugged packaging technologies. This MPS
will accept a 3-Phase input with a wide range of input voltage and frequency values while
delivering a well‑conditioned continuous 4000W, fixed DC output to the load. It is designed
and manufactured in SynQor’s USA facilities to comply with a wide range of military standards.
A communication/control port is available to permit monitoring and control by a host computer
system. Front panel LEDs provide information on the status of the MPS.
The electronic circuitry within the MPS-4000 Series products is designed, qualified 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
specifications for world-wide commercial utility applications.
The MPS-4000 Series products are designed and manufactured to withstand the harsh
environments and use encountered in military applications. 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 heatsink fins below the sealed chamber. Military-grade circular connectors are used, and optional
attached connector covers are available for when the cables are not attached. The MPS-4000
Series products comply with a wide range of testing according to MIL-STD-810G.
The SynQor MPS-4000 Series products are designed and manufactured in the U.S.A.
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Section II
General Product Information
Product Topology
The SynQor MPS-4000 Series products use an isolated topology that provides protection 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 profiles so that the input
power source is not subjected to these disturbances.
EMI filters are present at all external inputs and outputs.
AC
INPUT
AC to DC
w/ PFC
and
ISOLATION
OUTPUT
FILTERING
INTERFACE
CONTROL
OUTPUT
CAPACITOR
MAIN
DC
OUTPUT
Power flows from the AC INPUT through an AC-DC converter that has Power Factor Correction
(PFC) and high-frequency safety isolation. The DC outputs at various voltage and power levels are available. The DC can deliver up to
4000W (5250W transient) output. Bulk energy storage capacitors are connected to the mid-bus to help smooth imbalances in
power flow between the inputs and outputs of the MPS.
There is a communication/control port that provides a digital interface to a host computer system.
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Section II
General Product Information
Part Numbering Scheme and Options
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
@ Full Load*
Output Regulation
Network
MPS
4000: 4000W
1U: 1.73”
3: 3 Phase
W: 47-800Hz
2D: 28V
2E: 30V
4B: 48V
S00: Semi-regulated
E00: Ethernet/SNMP
Part Numbering Example: MPS-4000-1U-3W2ES00-E00 For valid part numbers, refer to the website or contact your local sales representative.
*Approximate output voltage at full load, output voltage has droop.
The MPS-4000 Series of products provide up to 4000W (5250W transient) of total output power. Each format has various options that can be specified 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 nominal output voltage of the MPS-4000 Series can be 28V, 30V, or 48V.
•The DC OUTPUT is semi-regulated, meaning that the voltage droops slightly as the output
current increases the facilitates current sharing when multiple units are connected in
parallel.
•RS232 serial port and logic-level I/O communication are included in the standard model. An Ethernet port providing web and SNMP interfaces is standard.
MPS in Transit Case Option
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Section II
General Product Information
Product Specifications
The following three pages show the electrical and mechanical specifications of the MPS-40001U high Series of products. Data sheets showing these specifications and other information
can be found at the web site http://www.synqor.com/MPS.
Status Indication Panel
MPS-4000-1U Unit
1.73"
1U
On/Off Switch
Air intake
17.00"
MPS-4000-1U Unit Rear Panel
DC
Output
Fan
Exhaust
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Ethernet User CONFIG
Port
I/O Port
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AC
Input
Fan
Exhaust
Ground Circuit
Stud Breaker
(1/4-20)
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Section II
General Product Information
Technical Specifications
INPUT CHARACTERISTICS
Operating AC Input
Voltage
Frequency
Input Power Factor
3-Phase, 80-265VrmsL-L*
47-800Hz
>0.98 at 47-65Hz
>0.97 at 400Hz
>0.92 at 800Hz
23A
25A
Maximum Input Current
AC Input Circuit Breaker Rating
(Continuous full load, 110VrmsL-L)
*Power Derating below 110VrmsL-L (see Figure 2)
OUTPUT CHARACTERISTICS
Total Output Power
Continuous
4000W
15s Transient
5250W
Nominal DC Output Voltage at No Load
28Vout
29.7V
30Vout
32.2V
48Vout
51.5V
DC Output Voltage over Line, Load & Temperature
(Semi-regulated, see Figures 3-5)
28Vout
30.3-27.6V
30Vout
32.8-29.9V
48Vout
52.5-47.9V
Maximum Output Capacitance
28Vout
255mF
30Vout
222mF
48Vout
86.8mF
Output Ripple Voltage (20MHz BW)
All Output Voltages
0.5% peak-to-peak of rated Vout
Hold-up Time
To -20% rated Vout, 4000W
10ms
Turn-on Delay
All Output Voltages
2s max.
Output Voltage Response to Load Transient
Iout steps from 50-75%
3% typ. / 6% max. deviation
at 0.2A/μs
100ms recovery
Over-voltage Protection
Cyclic Restart
Short Circuit Protection
Cyclic Operation
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110-120% rated Vout
115% rated Iout
ENVIRONMENTAL CHARACTERISTICS
MTBF 100kHrs
Temperature Methods 501.5, 502.5
Operating Temperature
Full Rated Power
Reduced Power per Figure 6
Storage Temperature
Altitude Method 500.5
Operating
Non-operating
Electromagnetic Capability
CE101
CE102
CS101
CS106
CS114
CS116
RE101
RE102
RS101
RS103
Environmental Tests
Shock/Drop
Vibration
Fungus
Salt Fog
Sand and Dust
Rain
EMI
Humidity
Mechanical Vibrations of
Shipboard Equipment
MIL-STD-810G
MIL-217F Ground Benign, Ta=25C
-40°C — +55°C
-40°C — +70°C
-40°C — +70°C
0 - 15,000 ft
0 - 40,000 ft
MIL-STD-461F
30 Hz - 10 kHz
10 kHz - 10 MHz
30 Hz - 150 kHz
10 kHz - 40 GHz
10 kHz - 200 MHz
10 kHz - 100 MHz
30 Hz - 100 kHz
10 kHz - 18 GHz
30 Hz - 100 kHz
2 MHz - 40 GHz
Method 516.6, Procedures 1,4,6
Method 514.6, CAT 5, 7, 8, 9, 24
Method 508.6
Method 509.5
Method 510.5, Procedures 1,2
Method 506.5
MIL-STD-461F
Method 507.5
Method 528
MECHANICAL CHARACTERISTICS
Standard 1U Chassis
Chassis Size (H x W x D)
1.73”(1U) x 17.00” x 20.42”
Case Material
Aluminum
Total Weight
28 lbs
Connectors
AC Input Connector
MS3470L14-4PW
DC Output Connector (+)
CGE2E18H5FB-16
DC Output Connector (-)
CGE2E18H5FWB-16
User I/O Ports
HD DB15 Female
Configuration 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.
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Section II
General Product Information
1U Mechanical Diagram
17.00”
[431.8]
.750” [19.05]
20.42”
[518.6]
19.34”
[491.1]
16.000”
[406.4]
.750” [19.05]
.750” [19.05]
1.49” [37.8]
.313” [7.95] TYP.
.874” [22.2]
POWER OUT
AUX
LOAD
MAIN
A
B
POWER IN
TEMP PGM1
C
COM
REM
BATTLE
MADE IN USA
FAN PGM2
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MPS
1.73” [43.9]
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Section II
General Product Information
MPS Efficiency
Figure 1 shows the typical efficiency with which the MPS-4000 series power supplies delivers
power to its DC OUTPUT from a 208VrmsL-L AC INPUT and an 115VrmsL-L AC INPUT:
100
95
Efficiency (%)
90
85
80
208 Vrms L-L Continuous
208 Vrms L-L Transient
75
115 Vrms L-L Continuous
115 Vrms L-L Transient
70
65
0
1000
2000
3000
4000
5000
Output Power (W)
Figure 1
Total Output Power that can be derived from the AC INPUT
The total MPS output power for the MPS-4000 series is rated at 4000W(5250W TRANSIENT)
for an ambient temperature as high as 55oC (131oF). However, when the AC INPUT voltage is at the low end of its range (<110VrmsL-L) or between
its low and high range (140VrmsL-L - 160VrmsL-L) the MPS will not be able to deliver its full rated
output power in both the steady-state and transient situations. Figure 2 indicates the total
steady-state and transient output power that the MPS can deliver under these conditions.
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Section II
General Product Information
MIL-STD-1399 115V L-L
MIL-STD-1399 200V L-L
Table II Steady-state
Table II Steady-state
Table III Transient
Table III Transient
6000
Output Power (Watts)
5000
4000
Transient 2s
Continuous
3000
MIL-STD-1399
3Φ Voltage
Ranges Shown
2000
1000
0
60
80
100
120
140
160
180
200
220
240
260
280
Input AC Voltage (VrmsL-L)
Figure 2
•If the AC INPUT voltage is above 110VrmsL-L, then the MPS can deliver its full rated output
power of 4000W from the AC INPUT for an ambient temperature as high as 55oC (131oF).
•If the AC INPUT is between 90VrmsL-L and 80VrmsL-L then the total output power that can
be derived from the AC INPUT linearly decreases from 3150W at 90VrmsL-L to 2750W at
80VrmsL-L (except for at the high end of the ambient temperature range – see below). For example, the total output power that could be derived from the AC INPUT would be
2900W at 85VrmsL-L as long as the ambient temperature is not above 50oC (122oF).
•Furthermore, there is a limited (and uncommon) range of AC INPUT voltage between
132VrmsL-L and 160VrmsL-L in which the total output power that can be derived from the AC
INPUT is also derated, as shown in the Figure 2 graph.
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Section II
General Product Information
Droop Characteristics - All Ouput Voltages
2s 20%
115Vrms L-L:
Maximum Transient
Duty and On-Time
208Vrms L-L:
120s 50%
2s 20%
115Vrms L-L:
Maximum Transient
Duty and On-Time
15s 20%
208Vrms L-L:
120s 50%
15s 20%
33.0
30.5
32.5
Output Voltage (V)
Output Voltage (V)
30.0
32.0
Transient
Operation
Regions
29.5
Transient
Operation
Regions
31.5
Continuous
Operation
Region
31.0
29.0
Continuous
Operation
Region
28.5
30.5
30.0
28.0
27.5
29.5
29.0
0
20
40
60
80
100
120
140
160
180
20
40
60
80
100
120
140
160
Output Load (A)
Output Load (A)
Figure 3B: 30Vout Droop Characteristics
Figure 3A: 28Vout Droop Characteristics
2s 20%
115Vrms L-L:
Maximum Transient
Duty and On-Time
0
208Vrms L-L:
120s 50%
15s 20%
52.0
Output Voltage (V)
51.5
51.0
Transient
Operation
Regions
50.5
Continuous
Operation
Region
50.0
49.5
49.0
48.5
48.0
0
10
20
30
40
50
60
70
80
90
100
Output Load (A)
Figure 3C: 48Vout Droop Characteristics
Figure 3
Note that the full rated output power of 4000W can be derived from the AC INPUT having a voltage
within this uncommon range for up to 15 seconds before the MPS will shutdown its output. Also note
that the MPS can drive at full rated power for a 2 second interval even if the AC INPUT voltage drops
below 110VrmsL-L.
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Section II
General Product Information
Power Cable Wiring Diagram
Looking at the rear panel, the MPS connector terminals have the following functions and locations:
Pin
A
B
C
D
AC INPUT
Function
Line 1
Line 2
Line 3
Ground
Key
A
DC OUTPUT
Function
-V
Key
B
DC OUTPUT
Function
+V
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A
D
B
C
A
B
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Section II
General Product Information
Warranty
SynQor warrants that the MPS product, including all accessories, will be free from defects in
materials and workmanship and will perform in accordance with its specifications (as set forth
in the SynQor Operator’s Guide and applicable datasheet) for one (1) year following the date
of shipment to the customer.
MPS products repaired or replaced pursuant to this warranty shall be warranted for the nonexpired portion of the warranty applying to the original equipment.
This warranty does not apply to (i) products damaged by abuse, misuse, neglect, improper
testing, accident or tampering, (ii) products subjected to adverse operating environments, (iii)
products operated outside the limits of their electrical specifications, (iv) products repaired
or modified by third parties or products which have been caused to fail by any product or
component not supplied by SynQor, (v) products which have been used in a manner contrary
to the specifications or guidelines set forth in the SynQor MPS Operator’s Guide or product
datasheet, or (vi) improper performance of products as installed in Buyer applications where
such products performed in accordance with product specifications prior to installation.
If SynQor determines that the product is defective SynQor will, at its option, repair or replace
the product or refund all or part of the purchase price therefor. Replacement product may
be new or refurbished equipment. To obtain a replacement or repaired product under this
warranty, the Buyer must contact SynQor Sales within the warranty period to obtain a Return
Material Authorization and shipping instructions. The Buyer must return the product in the
original packaging and pay all charges incurred in shipping the product back to SynQor. In
shipping the product back to SynQor, the Buyer assumes all risk of damage or loss in transit.
If SynQor determines that the product is defective, SynQor will pay any shipping charges in
sending the replacement or repaired product to the Buyer.
THIS WARRANTY IS BUYER’S SOLE AND EXCLUSIVE REMEDY FOR ANY CLAIM, WHETHER IN
CONTRACT, TORT OR OTHERWISE, AND IS IN LIEU OF ANY OTHER WARRANTY, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, ANY WARRANTY
OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTY OF
NONINFRINGEMENT OF THE INTELLECTUAL PROPERTY RIGHTS OF THIRD PARTIES. ALL SUCH
WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.
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Section II
General Product Information
Limitation on Liability and Remedy.
SynQor shall have no liability for any indirect, incidental, special or consequential damages
in connection with the transactions contemplated hereby or arising from the use or inability
to use the product, including without limitation, damages due to business interruption, lost
profits or lost goodwill, claims of third parties, or injury to person or property, whether based
upon breach of contract, negligence, strict liability, tort or other legal theory. In no event shall
SynQor’s total liability arising from the sale or use of, or inability to use, SynQor’s product
exceed the price paid for the product net of discounts and rebates. Neither party may bring a
cause of action under this warranty more than two (2) years after the cause of action arose.
Limitation on Use.
SynQor’s products are not authorized for use and should not be used, without the specific
prior written approval of an authorized officer of SynQor making specific reference hereto, in
any nuclear facility or application, or any other application in which failure or malfunction of
the product could reasonably result in loss of or harm to human life, or catastrophic damage
to property or the environment. Buyer will indemnify and hold SynQor harmless from any loss,
cost or damage resulting from Buyer’s use of the products in any such prohibited activity.
The foregoing is excerpted from SynQor’s Terms and Conditions of Sale - Military Power Systems,
available at this link: http://www.SynQor.com/Company - SalesTsandCs.html.
If there is a conflict between what is described in this Operator’s guide and SynQor’s online terms and
conditions, the online version shall govern.
PATENTS
SynQor holds numerous U.S. patents, one or more of which apply to most of its power converter products. Any that apply to the product(s) listed in this document are identified by markings on the
product(s) or on internal components of the product(s) in accordance with U.S. patent laws.
SynQor’s patents include the following:
5,999,417
6,222,742
6,545,890
6,594,159
6,731,520
6,894,468
6,896,526
6,927,987
7,050,309
7,072,190
7,085,146
7,119,524
7,269,034
7,272,021
7,272,023
7,558,083
7,564,702
7,765,687
7,787,261
8,023,290
8,149,597
8,493,751
8,644,027
9,143,042
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Section III
Operation
Set-Up
The recommended procedure for setting up the MPS is the following:
•Make sure the AC BREAKER on the rear panel of the MPS is in the OFF position.
•The AC breaker on the rear panel is classified as a supplementary protector and is
not designed for branch circuit protection. A suitable circuit breaker should be added
externally for the AC input if branch circuit protection is required.
•Connect the ground wire to the ground stud on the rear panel of the MPS.
•Connect the DC OUTPUT cables, first to the MPS and then to the load with the correct
polarity.
•Connect the USER I/O cables.
•Connect the INPUT cables, first to the MPS and then to the AC source.
•Turn on the source (if they have an up stream breaker).
•Move the AC BREAKER on the rear panel of the MPS to the ON position.
Start-Up
•VERIFY that all connections to the MPS are correct.
•If the AC source is present and within specifications, the three POWER IN LEDs on the
front panel will be green.
•Momentarily push the ON/OFF switch on the front panel of the MPS upward. The
switch can then be released and it will return to its normal (neutral) position.
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Section III
Operation
Shut-Down
•Shut down the equipment connected to the MPS.
•Push the ON/OFF switch on the front panel of the MPS downward and hold it in this position for 1 second (or more). The switch can then be released to return to its
normal position.
•The MPS will disable its outputs.
•It is not necessary to move the AC BREAKER on the rear panel of the MPS to the
OFF position.
Power Cable Connections
For safety reasons, the input and output power cables should be connected to the MPS before
the source of AC power is turned on, and before the MPS is turned on (see Section I: Warnings
and the SET-UP section above). Similarly, one should first turn off the MPS and the source of
input power before any power cables are disconnected from the MPS.
ALSO NOTE that when the MPS is turned on and delivering power to a load, and then another piece of
equipment is connected to the same output, it is possible that this connection will momentarily disrupt
the quality of the MPS’s output voltage.
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Section III
Operation
Cooling System
The SynQor MPS-4000 Series products are cooled by fans that draw air into the intake on the
front panel and exhaust it out the two fan ports on the rear panel. Care should be taken to
ensure there is no obstruction to this airflow, either at the front intake or the rear exhaust
ports. Similarly, care should be taken to avoid obstructing the fan blades.
The speed of the cooling fans is automatically controlled to provide adequate MPS cooling
while extending the life of the fan bearings. Under low ambient temperature and/or low MPS
output power the fans will be driven at a low speed. If the ambient temperature and output
power are such that the MPS cannot otherwise maintain its specified maximum temperature
for its internal circuitry, the fans will momentarily be driven at a speed that exceeds their rated
long-term running speed.
If the ambient temperature is low enough (for the level of power being delivered to the
load), the fans may not be on. This is not a malfunction. It is done to preserve the life of
the fans. If the fans are off, check the Fan Service Required LED on the front panel of the
battery pack. If it is GREEN, the fans are functioning properly and simply not needed under
the present conditions.
The fans are weather-proof and water-proof.
The MPS has two fans to provide redundancy for these exposed, moving components. With
only a single operating fan the MPS is still able to deliver 80% rated power at an ambient
temperature of 40°C, and it is able to deliver 60% of its rated power at an ambient temperature
as high as 55°C.
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Section III
Operation
Front Panel Indicators
To indicate the status of the MPS there are 16 LEDs on the front panel. These indicators are
described in this section.
LEDs
Each MPS has 16 LEDs, as shown below, that indicate the status of the operation of the MPS:
A0
A1
B0
B1
B2
B3
C0
P0
D0
D1
D2
E0
E1
E2
F0
P1
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Section III
Operation
• Power-In Indicators (LEDs in positions D0, D1 and D2)
The LEDs D0, D1, and D2 indicate the status of input phases A, B and C: Status is monitored on a line to
line basis:
LED Appearance
Description
Indication
Green
Input is Ready to Provide Load Power
Amber
Input is Not within Range
Red
Input is Not Present
Off
MPS is Off
• Power-Out Indicators (LEDs in positions A0 and A1)
The LED in position A0 indicates the status of the Auxiliary DC OUTPUT and the LED in position A1 indicates
the status of the Main DC OUTPUT, according to the table below:
LED Appearance
Description
Indication
Green
MPS is On and the Output Voltage is
Within Range
Amber
MPS is On but the Output Voltage is
Out of Range
Red
MPS is Off and the Output Voltage is Within Range
Off
MPS is Off
(Or the Auxiliary DC Output Option is not Installed)
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Section III
Operation
• Load Power Indicators (LEDs in positions B0 – B3)
The LEDs in positions B0 through B3 indicate the total output power of the MPS according to the table:
LED Appearance
Description
Indication
B0 Dimmed Green;B1-B3 Off
Total Load Power <25%
B0 Green; B1 Dimmed Green; B2-B3 Off
Total Load Power <50%
B0, B1 Green;
B2 Dimmed Green; B3 Off
Total Load Power <75%
B0, B1, B2 Green;
B3 Dimmed Green
Total Load Power <100%
B0; B1; B2 Green;
B3 Blinking Red
Total Load Power ≥100%
• MPS Cooling System Indicator (LED in position C0)
The LED in position C0 indicates the temperature and status of the cooling system for the MPS according
to the table below:
LED Appearance
Description
Indication
Green
Moderate MPS Temperature
(Fans Running at 33%)
Blinking Green
Warm MPS Temperature
(Fans Running at 67%)
Amber
Elevated MPS Temperature
(Fans Running at 100%)
Red
Maximum MPS Temperature
(Fans Running at 110%)
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Section III
Operation
• Fan Service Required Indicator (LED in position F0)
The LED in position F0 indicates whether the two cooling fans in the rear panel of the MPS are OK or if
their performance is degraded, according to the table below:
LED Appearance
Description
Indication
Green
Both Fans are OK
Amber
One or Both Fans Have Recently Had Degraded Performance
and Diagnostic Tests are Being Performed
Red
One or Both Fans Presently Have Degraded Performance
• Control Status (LED in position E0, E1, E2)
The LED in position E0, E1 or E2 indicates whether RS232 or Ethernet Port, Remote Enable/Shutdown or
Battle Short are active:
LED Appearance
Description
Indication
Green
E0: RS232 active or Ethernet Port Active,
E1: Remote Enable Active
Blinking Red
E2: Battle Short Mode Active,
Temperature Shutdowns Removed
Red
E1: Remote Shutdown Active
• Reserved (LED in position P0 & P1)
This section of the LED panel has been reserved for future use.
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Section III
Operation
Operating Environment
The SynQor MPS-4000 Series is designed for the extreme environmental conditions of military and
aerospace applications. All the electronic circuitry is contained in a sealed, weather-proof, shock-proof
chamber constructed of die-cast aluminum. Only the redundant, water-proof cooling fans are exposed
to the environment. The MPS will shut down if it is too hot and Battle Mode is not active.
The MPS (with cables connected or connector covers installed) has been qualified to the following
requirements of MIL-STD-810G:
MIL-STD-810G
Test Method
Name
Procedure
500.5
Low Pressure
I, II and III
501.5
High Temperature
I and II
502.5
Low Temperature
I and II
503.5
Temperature Shock
I
506.5
Rain
I
507.5
Humidity
NA
▪ 4” rain/hour
▪ 40 mph wind velocity
▪ >95%
508.6
Fungus
NA
▪ 28 day test
509.5
Salt Fog
NA
510.5
Sand and Dust
I and II
514.6
Vibration
Category 5
514.6
Vibration
Category 7
▪ General Exposure
514.6
Vibration
Category 8
▪ C-130 Aircraft level
514.6
Vibration
Category 9
▪ General Exposure
514.6
Vibration
Category 24
516.6
Shock
I, IV and Vi
528
Mechanical Vibrations of
Shipboard Equipment
I
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Details
▪ 15,000 ft. operating
▪ 40,000 ft. storage
▪ +55oC operating
▪ +65oC storage
▪ -20oC operating
▪ -20oC storage
▪ 10 cycles; >10oC/minute
▪ 5% salt solution
▪ 2 cycles (24 hr wet/24 hr dry)
▪ 20 mph blowing dust
▪ 40 mph blowing sand
▪ 5Hz (300 RPM)
▪ Loose Cargo
▪ PSD = 0.4 g2/Hz; 1-2000Hz
▪ Operating
▪ 20g/20ms; 40g/11ms; 75g/6ms
▪ 48 inch drop in transit case
▪ 30 degree tilt and drop
▪ Operating
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Section IV
Control Interface Details
Control Cable Connections
There are two high-density (three-row) DB15 connectors located on the rear panel of the MPS:
The User I/O female DB15 connector on the left is for an optional connection to a host/system
computer so that it can control the MPS and receive information regarding the status of the MPS.
The Configuration male DB15 connector on the right provides for synchronized startup and
shutdown operation of multiple interconnected units, using the SYN-9322 or SYN-9323 cable.
See description on Page 31.
The designation/location of the pins for the User I/O female high-density DB15 connector is
shown below:
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Section IV
Control Interface Details
Internal User I/O Circuits
+5V
1N4148
50k Ohms
7, 14, 15 Output Pin
2N3904
1N4148
Signal Common Pin
4, 5
I/O Circuits
+5V
100 Ohms
500 Ohms
PS2581L
8
+5V Pin
12, 13
Input Pin
User I/O Rear Panel Connector
15 Pin DSUB Female
1N4148
+5V
50k Ohms
TTL
6
Input Pin
Remote On/Off Switch Connections
+5V
100 Ohms
8
+5V Pin
I/O Circuits
500 Ohms
PS2581L
1N4148
500 Ohms
PS2581L
1N4148
12
REMOTE_START
Input Pin
OUTPUT ON
OUTPUT OFF
13
Remote On/Off Switch
SPDT Momentary
(ON) OFF (ON)
SHUTDOWN
Input Pin
Note: A 2PDT or 3PDT switch may be substituted for single control of 2 or 3 MPS machines, respectively.
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Section IV
Control Interface Details
Digital Input/Output Control Signals
There are 3 input and 4 output digital signals available on the User I/O female high-density
DB15 connector. The pin assignments and functions of these digital I/O signals are as follows:
High Density DB15 Female (15 Pin Connector)
Signal
PIN
Function
TX
2
RS232 DCE Device Transmit
RX
3
RS232 DCE Device Receive
GND
4, 5 Ground reference for all digital inputs and outputs
BATTLE_MODE
6
ACIN_GOOD
7
+5V
8
TTL-Input*, pull “low” to engage Battle Mode (disable internal over-temperature protection),
has internal pull-up to +5V.
Open collector* output where “low” indicates AC Input voltage is within range
Vout with minimal current drive usable as a pull-up voltage for open collector output signals.
Load must be <35mA
REMOTE_START
12 Drive this line “high” with ≥5mA to enable MPS outputs
SHUTDOWN
13 Drive this line “high” with ≥5mA to disable MPS outputs
OUT_OK
14 Open collector* output where “low” indicates Main DC Output voltage is within range
OVER_TEMP
15 Open collector* output where “low” indicates that the MPS is at or above its maximum temperature
*With an internal 50k Pull-up Resistor to 5V and ESD Protection Diodes.
Battle Mode disables internal over-temperature shutdown limits in the MPS hardware. Battle
Mode is indicated with a flashing red light in panel postion E2. This mode can be commanded
by pulling low on to I/O Port Pin 6, or via serial command BS ON.
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Section IV
Control Interface Details
RS232 Serial Interface
The same User I/O female high-density DB15 connector also provides for an RS232 interface
between the MPS and the host/system computer. The interface has a 115.2k baud with eight
data bits, no parity bit and one stop bit. The pin assignments and functions for this RS2332
interface are as follows:
Signal
Pin Number
Function
GND
4 and 5
Ground reference for RX and TX signals
RX
3
RS232 DCE/MPS Device Receive signal
TX
2
RS232 DCE/MPS Device Transmit signal
The RS232 port provides readback of MPS’s state, as well as the configuration and control
of the MPS’s operation. The port can be used from a standard terminal interface, or from a
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Section IV
Control Interface Details
Readback information that is available:
• AC Input Voltage
• AC Input Current
• AC Input Frequency
• DC Output Power
• External Switch Input Status
• Fan RPM
• Internal Temperatures
• Total Output Power
Parameters that are controllable through the interface:
• Battle Mode
• Fan diagnostics
• Fault Shutdown Synchronization Control
• On/Off Synchronization
• Output enable / disable
For a detailed description of the terminal interface see the SynQor website at:
http://www.SynQor.com/MPS/documents/MPS_User_Commands.pdf
Ethernet Interface
The optional Ethernet interface provides a web page based user interface for monitoring
and control of the MPS. The user can configure email alerts for MPS alarm conditions. The
interface also exposes an SNMP interface compliant to RFC-1628.
The Ethernet interface supports 10BASE-T and 100BASE-T standards. It utilizes a standard RJ45 connector, also allowing a metallic sealable circular military outer housing. The interface
supports auto-negotiation, polarity correction, and Auto-MDIX (detection and use of straight
through or cross-over cables).
IP address assignment can be done via DHCP or user entry of a static address. The interface
also supports a direct connection between the MPS and a host computer by including a DHCP
server internal to the MPS.
For a detailed description of the Ethernet port and SNMP implementation see the SynQor
website at: http://www.synqor.com/MPS/documents/MPS_Ethernet_SNMP_UG.pdf
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Section IV
Control Interface Details
Synchronized Operation of Multiple Units
Interconnecting multiple units via the Configuration port using cable SYN-9322 or SYN-9323
enables synchronized start-up, shutdown, restart, and fault behavior of connected units.
Turn-On, Turn-Off, Restart Control:
When an MPS device is in the Standby Mode (input power applied but output not enabled),
and its output is enabled via the front panel switch, remote enable input, or serial command,
all other MPS devices that are also in the Standby Mode will enable their outputs at the same
time. Likewise, when a unit is operating and its output is running, if its output is disabled via
the front panel switch, remote shutdown input, or serial command, all other MPS devices that
are also operating will disable their outputs at the same time. Finally, when an MPS restarts
after a fault event, it will coordinate its restart to be simultaneous with other MPS devices
restarting during the same interval. These features are enabled by default when the SYN9322 or SYN-9323 cable is utilized to interconnect multiple MPS devices. The features can be
disabled via the serial interface using the SYNCCON OFF command, and this setting is stored in
non-volatile memory. These features can also be disabled via the web interface.
Fault Synchronization Control:
When an MPS device is operating, and the output shuts down due to a load fault, such as a
short circuit, the Fault Synchronization Control will cause other MPS devices interconnected
via the SYN-9322 or SYN-9323 cable to shutdown at the same time. This feature is disabled by
default. It can be enabled via the serial interface by issuing the command, and the setting is
stored in non-volatile memory. The feature can also be enabled via the web interface.
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Section V
Maintenance
Fans
The fans on the rear panel have sealed bearings that do not require any maintenance.
Cleaning
The MPS-4000 unit has a sealed chamber for its electronics that is weather-proof. Only the fans
on the rear panel are exposed to the environment, and these fans are also weather-proof. The
unit can therefore be cleaned without concern of getting liquids inside the chamber. NOTE,
however, that if the cables have been removed from the connectors the connectors should
have their covers installed. If they are not, then care should be taken to not get excess liquid
on the connector terminals. ALSO NOTE that care should be taken to not get excess liquid on
the switch of the AC BREAKER on the back panel.
Cleaning should be done either with soap and water or with an Isopropyl alcohol and water
mixture. A soft cloth should be used.
Do not immerse the unit in water to clean it.
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Section VI
Trouble-Shooting Guide
Fault Conditions
The SynQor MPS has no user-serviceable parts within it. If it has an internal malfunction only
factory trained personnel should attempt to repair it.
There are, however, several external conditions that could cause the MPS to not operate as
desired. These external conditions can likely be corrected by the user.
The 16 LEDs on the front panel are the best and first place to look to determine what might
be wrong with the MPS. The table on the next several pages is therefore organized by what
these LEDs indicate, and for each indication there is a listing of what might possibly be wrong. The front panel LED array is shown below. The designations of the 16 LEDs in this array are
used in the following table.
A0
A1
B0
B1
B2
B3
C0
P0
D0
D1
D2
E0
E1
E2
F0
P1
LED
D0,
D1,
D2:
AC INPUT
Power LED
A0, A1:
DC OUTPUT
Power LED
Indication
LED is OFF
Possible Problem(s)
•The AC INPUT power source is not turned on.
•The AC INPUT cable is not connected or it is wired wrong.
•The AC Breaker on the rear panel is OFF.
•The MPS is OFF and needs to be turned ON.
LED is AMBER
•The AC INPUT voltage is either too low or too high.
LED is RED
•The AC INPUT voltage is missing at least one phase on its source.
LED is OFF
•The optional auxillary DC OUTPUT is not available on the unit. (A0)
•The MPS is OFF and needs to be turned ON.
LED is AMBER
•The DC OUTPUT load is too high.
•The DC OUTPUT is shorted within the cable or a load.
•Some other source of power is connected to the DC OUTPUT.
LED is RED
•The MPS has been turned OFF, but due to a malfunction within the
MPS it is still running and providing an DC OUTPUT voltage.
•Some other source of voltage is connected to the DC OUTPUT and is
powering it when the MPS is disabled.
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Section VI
LED
Indication
C0:
•Total MPS load power is greater than 4000W. The MPS may still be
delivering its specified output voltage because the load power is not
high enough to trigger the power limit circuitry.
B0 – B3 are all OFF
•No power is being delivered to the load.
•The MPS is OFF and needs to be turned ON.
•The loads or output cables are not connected.
•The loads are all turned off.
•The loads are simply not drawing any appreciable power at the time.
LED is BLINKING
GREEN
•Indicates that the fans are running at 67% of their rated speed. There is no problem.
LED is AMBER
•Indicates that the fans are running at 100% of their rated speed. There is no problem, but the unit is operating at a high ambient
temperature and a high load combination.
LED is RED
•Fans are running at 110% of rated speed to keep the unit cool. The
maximum recommended temperature may be exceeded, but the
fans are keeping things cool enough to avoid triggering the overtemperature shut-down circuitry.
LED is AMBER
•One or both fans have recently had degraded performance but seem
to be ok now. The MPS is running a diagnostic test.
MPS Cooling
System LED
F0:
Fan Service
Required LED LED is RED
All LEDs:
Possible Problem(s)
B3 is BLINKING RED
B0 – B3:
LOAD POWER
LEDs
Trouble-Shooting Guide
All LEDs are OFF
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•One or both fans presently have degraded performance, even
if they are running, and service is recommended at the earliest
convenient time.
•Ensure that the fan blades are not obstructed from turning
•The MPS is OFF and needs to be turned ON.
•The AC INPUT power is not turned ON.
•The AC Breaker on the rear panel is OFF.
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Section VI
Trouble-Shooting Guide
Two other conditions should be mentioned:
•The fans are off when the MPS is running
It is normal for the fans to be off, even if the MPS is running and delivering power to the load,
as long as the temperature of the MPS is low enough. If the Fan Service Required LED (F0) is
green, both of the fans are OK, even if they are not running.
•The MPS does not turn off when the ON/OFF switch is pushed down
When the ON/OFF switch on the front panel is pushed down, the MPS does not respond to
this signal for approximately 1 second. This is done to ensure that the MPS is not accidently
turned off. If the user does not hold the ON/OFF switch in the OFF position for a full second
before releasing it, the MPS will not turn off.
Other possible situations that are the result of external issues that a user could
likely correct are related to:
•Loads that draw a large surge of current at start-up
Some loads draw a very large amount of current when an input voltage is first applied to them. This might happen when the MPS is first turned on if the load is already connected to the MPS. Or it may happen when the load itself is turned on and/or connected to the DC OUTPUT of a
MPS that is already running. Common examples of such loads are motors and incandescent
lights, but some electronic equipment can also display this characteristic.
Several problems could arise with such a load:
▪ A newly started load disturbs the existing MPS loads.
If this disruption of existing loads is a problem, then the solution is to make sure the
loads that display this start-up surge characteristic are all started first, or that all loads are
started at the same time.
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MPS
Operator’s Guide
MPS-4000 Series
Military-Grade Power Supply
006-0006715 02/04/16 Rev E
Advancing The Power Curve
1.888.567.9596 (USA only) | SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |
Made in USA
®
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