SynQor MPPS-4000-270 Series Operator's Manual

3-phase c to dc power supply

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3-P

DC P

hase

ower

uPPly

Operator's Guide

3Φ to DC

MPPS-4000-270 Series

MPPS-4000-270

N+M R

EDUNDANCY

Made in USA

www.synqor.com

1.888.567.9596 (USA only)

SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA

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Summary of Contents for SynQor MPPS-4000-270 Series

Page 1 DC P hase ower uPPly Operator’s Guide 3Φ to DC MPPS-4000-270 Series MPPS-4000-270 N+M R EDUNDANCY Made in USA www.synqor.com 1.888.567.9596 (USA only) SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA...
Page 2 Power Cable Wiring Diagram .........................10 Section III Operation Set-Up ..................................11 Start-Up ..................................11 Shut-Down ................................11 Power Cable Connections ..........................12 Programming The Output ..........................12 Front Panel Indicators ............................15 Audible alarm ...............................19 Operating Environment............................20 006-0007309 03/19/2024 Rev A ii of iii MPPS-4000-270 Guide www.synqor.com...
Page 3 Remote On/Off Switch Connections....................27 Digital Input/Output Control Signals ......................28 Ethernet Interface ..............................28 RS-232 Serial Interface ............................29 Section VI Maintenance Fans ..................................30 Cleaning .................................30 Section VII Trouble-Shooting Guide Fault Conditions ..............................31 006-0007309 03/19/2024 Rev A iii of iii MPPS-4000-270 Guide www.synqor.com...
Page 4 Warnings Hazardous Voltages The INPUT AND OUTPUT POWER connectors and cables of the SynQor 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.
Page 5 Warnings Hazardous Energies The INPUT AND OUTPUT POWER connectors and cables of the SynQor MPPS may be a 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 MPPS Unit’s chassis or ground.
Page 6 Section II General Product Information Product Description SynQor’s Military 3-Phase AC to DC Power Units are designed for the extreme environmental and demanding electrical conditions of Military/Aerospace applications. SynQor’s MPPS-4000-270 units incorporate field proven high efficiency designs and rugged packaging technologies. The MPPS-4000-270 will accept an AC 3-Phase Input with a voltage and frequency range of 360-528 Vrms (line to line) and 47-65 Hz. The unit will deliver a tightly regulated, programmable DC output to the load.
Page 7 Section II General Product Information Product Topology The SynQor MPPS-4000-270 Series products use an isolated topology that provides protection to the load from spikes, noise, surges, brownouts, blackouts, etc. in the input power source. 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 MPPS external inputs and outputs.
Page 8 Section II General Product Information Part Numbering Scheme and Options This table shows the part numbering scheme for the full line of SynQor MPPS products: Base Models Model Number Power Height (W x D x H) Weight MPPS-4000-1U- 4000 W 5000 VA 1U (17.00"...
Page 9 Section II General Product Information Product Specifications The next pages show the electrical and mechanical specifications of the MPPS-4000-270 Series of products. Data sheets showing these specifications and other information can be found at the web site https://www.synqor.com/product-guide/military/system/rack-mount/ac-dc-power-supply. MPPS-4000-270-1U UNIT Front Status Indication Panel 1.73" On/Off Switch Air intake 17.00" MPPS-4000-270-1U UNIT Rear Ground Ethernet User CONFIG Circuit Stud Port Port Input Breaker Output Exhaust...
Page 10 HD DB15 Female Ethernet Port Amphenol RJF22N00, Code B Cooling Exhaust Fans Sound Pressure Level (SPL) 64 dB(A) Air Flow 0.92(m /min) 32.5 CFM Two fans in system; above specs are for each fan separately. 006-0007309 03/19/2024 Rev A 7 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 11 22.42" 18.700" [569.4] [474.98] 19.450" [494.03] 21.34" [541.9] 9.750" [247.65] 0.75" [19.1] 0.75" [19.1] 0.55" [13.9] UNIT 0.313" 17.00" [431.8] MOUNTING [7.94] HOLES 0.625" 8-32 0.250" [15.88] 1.73" [43.9] MPPS 006-0007309 03/19/2024 Rev A 8 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 12 360 Vrms L-L 440 Vrms L-L 528 Vrms L-L DC Output Power (kW) Figure 1 Total Output Power The total MPPS output power for the MPPS-4000-270 series is rated at 4000 W for 15 seconds. These ratings apply at an ambient temperature as high as 55 C (131 Output Power vs Output Voltage 15s Transient Continuous Output Voltage (V)
Page 13 AC INPUT Function Line A (360-528) Line B (360-528) Line C (360-528) Ground Warning: Pin D should never be connected to a line Voltage DC OUTPUT Function Vout+ Vout_RTN Ground 006-0007309 03/19/2024 Rev A 10 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 14 • Connect the ground wire to the ground stud on the rear panel of the MPPS. • Connect the DC OUTPUT cables, first to the MPPS and then to the load. • Connect the USER I/O cables. • Check that pin D in the input connector is not connected to a line voltage. On input cables provided by SynQor, pin D (input AC ground) is connected to the green color wire. • Connect the INPUT cables, first to the MPPS and then to the AC source. • Turn on the source (if it has an up-stream breaker). • Move the AC BREAKER on the rear panel of the MPPS to the ON position.
Page 15 4500 W when set to 200 V, 22.5 A. If the output voltage is set to 400 V, the MPPS will automatically scale back the current to 11.25 A so as not to exceed 4500 W. To set the voltage through the web page, navigate to the control page. Under “Configuration”, enter the desired output voltage in volts and the desired current limit in amps. Click update to apply the changes. These values are stored in non-volatile memory, and do not need to be reentered after the MPPS-4000-270 is power cycled. 006-0007309 03/19/2024 Rev A 12 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 16 Section III Operation Setting the output voltage and output current using the web interface 006-0007309 03/19/2024 Rev A 13 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 17 To set the voltage through the RS-232 interface, configure the RS-232 terminal with 115.2 k baud, 8 data bits, no parity, and one stop bit. Using a third party terminal application such as HyperTerminal, send the following commands: SET ILIM x [mA] SET VNOM x [V] Example: Set Vout to 200 V, ILim to 15 A. SynQor>SET VNOM 200 Flash Updated. SynQor>SET ILIM 15000 Flash Updated. Note that after each command the system will return “Flash Updated”. This indicates that the values have been stored in non-volatile memory, and do not need to be reentered when the MPPS-4000 is power cycled.
Page 18 To indicate the status of the MPS or MPPS there are 16 LEDs on the front panel. These indicators are described in this section. LEDs Each Unit has 16 LEDs, as shown below, that indicate the status of the operation of the Unit: LOAD FAN PGM1 ON FAULT BATTLE TEMP OUTPUT PGM2 006-0007309 03/19/2024 Rev A 15 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 19 Unit is “On” and the Output Voltage is Green Within Range Unit is “On” but the Output Voltage is Amber Out of Range Unit is “Off” and the Output Voltage is Within Range Unit is “Off” 006-0007309 03/19/2024 Rev A 16 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 20 Indication Green Both Fans are “OK” One or Both Fans Have Recently Had Degraded Amber Performance and Diagnostic Tests are Being Performed One or Both Fans Presently Have Degraded Performance 006-0007309 03/19/2024 Rev A 17 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 21 LED Appearance Description Indication E0: RS-232 active or Ethernet Port Active, Green E1: Remote Enable Active E2: Battle Short Mode Active, Blinking Red Temperature Shutdowns Removed E1: Remote Shutdown Active 006-0007309 03/19/2024 Rev A 18 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 22 DC output voltage is low. MPPS is likely in current limit. MPPS may Three need to be power cycled to clear this condition. Four One or Both Fans have Presently a Degraded Performance 006-0007309 03/19/2024 Rev A 19 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 23 Section III Operation Operating Environment The SynQor MPPS-4000-270 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.
Page 24 HD DB15M to DB9F (RS232, 10’) HD DB15M to DB15M (RS232 and Digital I/O, 10’) SYN-9305 Mil-Circular to RJ45 (Ethernet, 10’) SYN-9321 Configuration Cables HD DB15F to DB15F (2 Units Parallel, 3’) SYN-9341 HD DB15F to DB15F (3 Units Parallel, 6’) SYN-9343 SYN-9344 HD DB15F to DB15F (4 Units Parallel 9’) HD DB15F to DB15F (5 Units Parallel 15’) SYN-9345 006-0007309 03/19/2024 Rev A 21 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 25 MPPS. Connecting the MPPS to a supply that exceeds its maximum rating will cause permanent damage to the MPPS. External Diode External Source Load — MPPS-4000-270 MPPS diode ORing with 3 party auxiliary supply 006-0007309 03/19/2024 Rev A 22 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 26 DC OUTPUT DC OUTPUT PEGND PEGND PEGND V+ V- TO LOAD The cable sizes for the blue and red cable sections show above are as follows: Blue Cable Section Red Cable Section Minimum Wire Size Minimum Wire Size #10AWG (6 mm #6AWG (16 mm 006-0007309 03/19/2024 Rev A 23 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 27 Either Vout- or Vout+ can be connected to chassis ground. Internal protection devices clamp the output to within ±1000 V of chassis ground. For margin, the output must not be grounded to another source that sees more than ±300 V with respect to chassis ground. As an example, Vout- should not be tied to the AC line of a grounded AC system. 006-0007309 03/19/2024 Rev A 24 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 28 CONNECTIONS. ALL AC INPUT AND OUTPUT CABLE CONNECTORS MUST BE INSTALLED PRIOR OPERATION. DISCONNECTED CABLE CONNECTORS MAY HAVE VOLTAGES PRESENT FROM ANOTHER UNITS IN A GROUP AND COULD POTENTIALLY BE HARMFUL. 006-0007309 03/19/2024 Rev A 25 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 29 MPPS and receive information regarding the status of the MPPS. The Configuration male DB15 connector on the right provides for synchronized startup and shutdown operation of multiple interconnected units, using the SYN-9341, SYN-9343, SYN-9344 or SYN-9345 cables. See the “Possible configurations of the DC OUTPUTs” on page 22 for supported configurations details. The designation/location of the pins for the User I/O female high-density DB15 connector are shown below: 006-0007309 03/19/2024 Rev A 26 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 30 +5V Pin I/O Circuits 500 Ohms PS2581L REMOTE_START OUTPUT ON 1N4148 Input Pin OUTPUT OFF 500 Ohms PS2581L Remote On/O Switch SHUTDOWN 1N4148 SPDT Momentary Input Pin (ON) OFF (ON) Note: A 2PDT or 3PDT switch may be substituted for single control of 2 or 3 MPPS machines, respectively. 006-0007309 03/19/2024 Rev A 27 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 31 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 configured to be acquired by the unit automatically via DHCP or set up through a static address entry via the web interface. The Ethernet interface also provides a local DHCP server that allows direct MPPS to host computer connections. For a detailed description of the Ethernet port and SNMP implementation see the SynQor www.synqor.com/MPS-ESNMP website at: 006-0007309 03/19/2024 Rev A...
Page 32 • AC Input Frequency • E xternal Switch Input Status • Fan RPM Parameters that are controllable through the interface: • O utput voltage (25 – 400 V) • Current limit (0.2 – 24 A) • O n/Off Synchronization • Battle Mode • A larm enable / disable • Fan Diagnostics • O utput enable / disable For a detailed description of the terminal interface see the SynQor website. https://www.synqor.com/document-viewer?document=MPS_User_Commands.pdf 006-0007309 03/19/2024 Rev A 29 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 33 Maintenance Fans The fans on the rear panel have sealed bearings that do not require any regular maintenance. Fan assemblies are user replaceable with kits available from SynQor. Please contact the SynQor factory for obtaining fan replacement kits. Cleaning The MPPS 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.
Page 34 Section VII Trouble-Shooting Guide Fault Conditions The SynQor MPPS has no user-serviceable parts within it other than the cooling fans. If the unit has an internal malfunction only factory trained personnel should attempt to repair it. There are, however, several external conditions that could cause the MPPS 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 Unit. 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.
Page 35 • To reset, the Unit OUTPUT must be turned “OFF” and then “ON”. • One or more fans have encountered a fault or degraded performance. Four tones • The Unit may still operate with degraded fan performance, but should be serviced soon. Ensure the fan blades are not obstructed. 006-0007309 03/19/2024 Rev A 32 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 36 “ON” DC OUTPUT of a Unit that is already running. Common examples of such loads are motors and incandescent lights, but some electronic equipment can also display this characteristic. 006-0007309 03/19/2024 Rev A 33 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 37 MPPS’s DC OUTPUT to be triggered, which in turn causes the output voltage to drop. The drop could cause the existing loads to be disturbed. Furthermore, if the voltage drops is far enough below the rated limit, the MPPS will turn “OFF” its DC OUTPUT and initiate a new start-up sequence. This latter action could cause an interruption of existing running loads. If this disruption in the loads is a problem, then the solution is to make sure that loads with large startup surges are started first, and then proceed to start the rest of the loads. 006-0007309 03/19/2024 Rev A 34 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 38 MPPS may determine that the AC INPUT is out of range and proceed to shut down. After this occurs, no current is being drawn through the input cables and terminals once again, the MPPS detects that the AC INPUT voltage is back to normal, and begins the startup sequence once again after a 1 second delay. The cycle will continue to repeat over and over, until voltage drop in the input circuit is corrected. The following are possible solutions to this problem: 1) make sure that the cable diameter for the required length is sufficient to deliver the full amperage to the MPPS unit, 2) tighten the distribution panel/breaker terminals or 3) clean any contamination or corrosion buildup on all terminals and connectors. 006-0007309 03/19/2024 Rev A 35 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 39 Notes 006-0007309 03/19/2024 Rev A 36 of 37 MPPS-4000-270 Guide www.synqor.com...
Page 40 DC P hase ower uPPly Operator’s Guide MPPS-4000-270 Series 006-0007309 03/19/2024 Rev A Made in USA www.synqor.com 1.888.567.9596 (USA only) SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA...

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