MRF2800
MRF2800
MRF2800
Chapter 1 Introduction 3
Chapter 4 Signals 11
4.1 Signals Overview 11
4.1.1 Basic Signals 11
4.1.2 Extended Signals 11
4.1.3 Extended Signals + Float/Boost Control 11
4.2 Isolated Signals 12
4.2.1 Signals and LEDs 12
4.2.2 Signals Configuration 12
Chapter 8 Maintenance 17
The MRF2800 Rectifier range are a.c./d.c. converters specifically designed for high power battery charging
applications in stand-by systems.
All models have sine wave corrected input and most operate from 230V nominal 50/60Hz ac input. The
MRF28H54BV50 operates from 277V nominal 50/60Hz AC input and provides a nominal output voltage of
54.5V. An output power of 2800W is available at a nominal voltage of 54.5V (max ambient 65C) or 27.25V
(max ambient 55C). Cooling is provided by an internal, variable speed fan.
MRF2800 have rear hot plug connectors suitable for blind mating the rectifier into a suitable shelf such as the
APC MS28* family.
One or more further characters can be appended to the above base part numbers :
| V or H is used to denote the front panel style, Vertical units have a 4U high front panel, while Horizontal
units have a 3U high front panel, with the rectifier body rotated through 90 degrees.
| N is used to denote non-SELV units, with a higher 63V maximum output.
| Digits 00 though 99 denote a specific configuration of the product, e.g. output voltage set to a non-
standard value
Throughout this handbook product numbers containing one or more * characters refer to products in the above
table where the * can represent any character valid for this table. For example, MRF28H54* can be any of
MRF28H54A or MRF28H54B or MRF28H54D.
For the complete electrical and mechanical specification refer to the product data sheet.
The rectifier is intended to be accessible only to authorised personnel; user access should be prevented by
mounting in a suitable enclosure. See chapter 7 for further information regarding safety approvals and EMC.
WARNING Hazardous voltages exist at various points within the unit. Disconnect the mains supply and wait at
least 3 minutes before removing any covers.
If the unit requires servicing it is recommended that it be returned to the manufacturer at the address given.
Any repairs attempted must be carried out by qualified personnel conversant with modern switch mode power
supply technology.
All models are designed for mounting in rack systems with the internal fan providing cooling. Provision must be
made for the free flow of cooling air into the front face of the rectifier, and free exit from the rear (connector)
face.
MRF2800 rectifiers are designed to thermally protect in situations where there is inadequate airflow; the
protection mechanism is described in detail in chapter 6.
3.3 Connections
MRF2800 rectifiers will not operate until pin a3 (post mate enable) is connected to pin b8, and a 1 second delay
is included to allow the connector mating process to be completed when the unit is pushed into its rack before
power is available from the output connectors.
All versions of MRF2800 rectifiers include an output protection diode which will prevent current feedback into
the unit when the output is connected to an external power bus.
Units with basic signals do not have any external adjustment potentiometers. Output voltage can be adjusted
by the application of an external voltage trim port. (See below).
Units with extended signals (see chapter 1) have two output voltage levels, Float and Boost. These two levels
are set by independent front panel pots. Selection of float or boost voltage is done with either a front panel
switch, OR a digital input signal (pin b2). The default condition is float.
In addition, "D" version units have independently adjustable current limits for the float or boost condition, and a
front panel adjustable overvoltage trip level.
If the connections from the rectifier to the load are very short, then no load current sharing between the rectifiers
will occur. The rectifier with the highest set output voltage will supply all the load current until it reaches its
current limit point, when the rectifier with the next highest set output voltage will start to provide load current,
until it reaches its current limit point; and so on. The rectifiers are able to operate under these conditions, but it
may be desirable to distribute the load more evenly.
Some load current sharing can be achieved by arranging the connections from the rectifiers to the load to be
star-point connected at the load and allowing the output voltage to droop slightly via each load lead. Resistance
as small as 3-4mΩ in the connections between the rectifiers and the star point will cause reasonable current
sharing.
Figure 3.1 shows the recommended methods of connection in forced current share.
For local sensing, Figure 3.1A, it is therefore desirable to star-point the negative power connections to achieve
the best load current sharing. The range of control of the forced current share port is limited to a +1%
differential in the output voltage of paralleled rectifiers. Thus for systems using local sensing it is recommended
that the positive power connections are star-pointed too, to limit the differentials between sensed output
voltages.
When using remote sensing, Figure 3.1B, the power connections can be made in any convenient manner,
provided the respective positive and negative sense terminals of each rectifier are connected together and
single sense connections made at the load.
Rectifiers are supplied with the sensing set to local by default. This can be adjusted by altering the settings of
the red DIL switches which are accessible from the outside of the unit, switch 1 controls the connection of +ve
sense, switch 2 controls the connection of -ve sense. For switch access and setting see chapter 5.
If circuit breakers are used in either the positive or negative power connections, then local sensing must be
employed. This ensures that each rectifier can locally control its output when not connected to the rest of the
system.
While the connection methods of Figure 3.1 are the most desirable, the rectifier is tolerant to many variations of
connection. While current sharing is not guaranteed if other methods are used, the rectifier will not be damaged
and will not produce voltages above the overvoltage trip level.
The group of connections +sense, marginate down, v-trim and -sense shown in figure 3.2 allows the user to
accurately control the output voltage of the rectifier. The pins allocated to these connections are detailed in the
appropriate table in chapter 2. It is intended that the rectifier can be operated with no connections made to these
pins at all. In this condition DIL switches 1 and 2 internally connect the positive and negative sense terminals to
the positive and negative output terminals respectively. This provides local voltage sensing and the voltage at
the output terminals is regulated very accurately.
A preset reduction in the output voltage of typically 2.5V can be achieved if marginate down is connected to
+sense.
An external control circuit can be used to vary the output voltage over a limited range. V-trim is connected to the
voltage control circuit via a high impedance. The open circuit voltage at this point is preset to 5.1V (via 32kΩ)
with respect to -sense; output voltage adjustment is achieved by sinking or sourcing current (1mA max.) through
this port. As the voltage applied to v-trim is moved from +5.1V to +10V the output voltage will linearly reduce
from 54.5V to 48V (27.25V to 24V for 27V product); moving the voltage applied to V-trim from +5.1V to +0V will
cause the output to linearly increase from 54.5V (27.25V) to the OVP trip level. The V-trim lines of all units in a
system may be linked for common control of all the rectifiers (the -sense lines must also be linked), but this
connection must be driven by an external voltage source. If this is not done, then rectifier failure, hot-plugging
and system power-up will cause significant deviations in output voltage. In complex power systems, the "Power
Management System" will usually have an analogue output for adjusting system voltage, and this can be
connected to the V-trim port.
The circuit shown below can be used to drive the V-trim port on multiple rectifiers, with pot P1 allowing
adjustment of all rectifiers simultaneously. It is recommended that one of these circuits to fitted to each rectifier
shelf in a rack system. The power management system can still be connected via R9, and will override the local
pot setting.
A fixed offset down can be applied to the output voltage by setting red DIL switch 3 ON; this will reduce the
output voltage by 5V (2.5V for 27V product). For DIL switch access and setting see chapter 5.
The current monitor output produces an analogue signal referenced to -sense that is proportional to the current
being delivered by the rectifier; the gain is 0.1V/amp for both 54V and 27V rectifiers (i.e. 50A results in 5.0V). A
suitable ammeter can be directly connected as the output impedance of the signal is 5.1kΩ.
Rectifiers are supplied with the current limit characteristic set by default to foldback; the current limit
performance is illustrated in figure 3.3 below. Alternatively, the characteristic can be altered to constant current
by setting red DIL switch 5 OFF
A 12V 100mA auxiliary supply is provided which is floating with respect to the rectifier output, with its negative
return line (0V float) connected to optos common This supply is protected against short circuit and excessive
voltages connected in parallel. It can be used to power any external signal or control circuitry the user may wish
to connect to the rectifier, and is present whenever AC input is connected to the rectifier regardless of the
rectifier output status.
A comprehensive signals package is available for MRF2800 rectifiers. Basic signals are included with every
version, whereas products with part number suffix B or D (see table in chapter 1) have signals cards fitted which
provide extended signals.
Rectifiers with part number suffix A have the following basic signals:
O/P healthy relay contacts (Green LED mimics o/p healthy contacts)
Remote sense Voltage trim port Marginate down
Current share port Analogue current signal
Rectifiers with part number suffix B have the following extended signals in addition to the basic set described
above.
Digital inputs:
Inhibit / OVP reset Programme down
Digital inputs and outputs are isolated from the rectifier power output with optocouplers and are described in
section 4.2 below.
Rectifiers with part number suffix D have the following extended signals in addition to the basic set described
above.
Digital inputs:
Inhibit / OVP reset Programme down Boost select
Digital inputs and outputs are isolated from the rectifier power output with optocouplers as described in section
4.2 below.
The selection of the float or boost condition can be made in one of two ways; either the front panel switch can
be used or the isolated digital input. If the front panel switch is set to boost the rectifier cannot be set to float
using the digital input, so for remote control of this function the front panel switch should be set to float.
Note
Connector numbering shown in figure 4.1 is
internal to the rectifier and different from the
customer connect pins. For access to the signals
shown in figure 4.1 consult the appropriate
connections tables in chapter 2.
Signal setting switches on the MRF28H**B version are accessible trough the rear panel grill.
SW3E 5 Enable overvoltage opto output Disable overvoltage opto output OFF
set for
SW3F 6 54V operation 27V operation
unit type
The MRF2800 series rectifiers are designed to supply 2.8kW output power up to a maximum ambient of 65C
(55C for 27V). The current limit will operate slightly above the 2.8kW level, typically at 51A for a 54V unit (102A
for a 27V unit). Thus demands for power up to the level of current limit will be met with a well regulated output
voltage, and if system demand increases further the rectifier will provide a constant current by allowing its output
voltage to fall. As the output voltage falls below 40V (20V for 27V rectifier) the output current may foldback or
remain constant down to short circuit (see section 3.7.2 above).
Should the rectifier be inadequately cooled due restricted airflow or too high an ambient temperature, its
thermal protection circuit will limit the available output current. This condition will be indicated on units fitted with
the extended signals by the yellow thermal control LED lighting, and by the thermal control opto output pulling
low. The operation is summarised by the graphs below:
The operation of the circuit will be as follows: With the rectifier running in an inadequately cooled condition, one
of the three internal sensors will eventually exceed its maximum designed run temperature of 90ºC. At this point
the unit will enter the thermal control region, indicated by the thermal control LED lighting, and the available
output current (i.e. the current limit value) will be reduced. However, if the system demand for current is less
than the current limit point, no effect will be seen on the output voltage or current. If the unit continues to heat
up, the available current will continue to reduce, eventually as far as 40A (80A for a 27V unit). If the system
demand is greater than 40A (80A for a 27V unit), the rectifier's output current will be reduced to this value
(causing the output voltage to drop) and the red current limit LED (enhanced alarms units) will light. If the unit
continues to heat further the power conversion stage will be inhibited and the unit output will fall to zero:
extended alarms units will have the red overtemperature LED lit as well as the thermal control LED. This
condition will remain until the unit cools internally, then output power will be restored. Once output power is
restored, the unit will heat up and the above process will repeat unless the cooling process is improved or the
system demand is reduced.
An example of the above process with numbers may help to clarify the operation of the thermal protection. An
MRF28H54B rectifier is running at 54.5V and the system demand (load) is 45A. The unit is capable of supplying
51A. Due to inadequate cooling, the unit heats and the thermal control LED lights. At this point the unit
continues to supply 54.5V at 45A, but the available output current is reduced. As the unit continues to heat, the
available output current gradually reduces and eventually becomes 44.9A. At this point the current limit LED
lights, the output current reduces to 44.9A and the output voltage falls below 54.5V: the unit power dissipation is
reduced. If the unit continues to heat, the available current drops further and the output voltage falls
correspondingly; the system receives less current from the rectifier and its power dissipation drops. At this point
equilibrium may be reached with the output current limited to a value between 40A and 45A and the unit
temperature stabilised. However, if the unit continues to heat further, the output current will be reduced to 40A
(output voltage falls also) and further heating will switch off the output. When the output is switched off, the red
overtemperature LED lights, the current limit LED goes off, but the thermal control LED remains on.
When the output voltage reduces below 40V (20V for a 27V unit) the green output healthy LED (and output
healthy relay) will switch off. This may occur when the unit is in current limit (depending on the value of load), or
may not occur until the unit output is shut down due to overtemperature.
Note: Units without enhanced alarms (MRF28H**A) will operate exactly as described above but without the
LED indications on the front panel. These units have only the output healthy LED.
The internal cooling fan operates at a variable speed, which is determined by internal temperatures of key
components within the rectifier. These temperatures are a dependant upon both load and the external ambient
i.e. the fan speed will increase in response to high loads and/or a raised ambient temperature.
In average room ambient (25C) the fan will remain at minimum speed for loads of typically less than 75% of full
load.
To overcome potential problems associated with viscous fan bearing lubrication during low temperature starts,
the fan is run at maximum speed after switch on for a period of 30 seconds.
7.1.1 CE Mark
The rectifier is CE marked to the European Low Voltage Directive (LVD) 73/23/EEC amended by 93/68/EEC,
relating to the Safety of Electrical Equipment. The rectifier is designed for incorporation within apparatus. For
user safety, the enclosing apparatus must protect the user against accidental contact with any electrical hazard
associated with the power supply and hot surfaces.
The rectifier is approved to EN60950 / IEC950 and the requirements of these specifications must be met when
installing the rectifier.
The output power is greater than 240VA. All units other than rectifiers with part number suffix N are reliably
SELV.
7.2 EMC
The rectifier complies with the following: Conducted emission from the input terminals to meet EN55022
(Information technology equipment) level B. Conducted emissions from the load terminals as per EN 300 386-2.
Radiated emission from the power supply to meet EN55022 (Information technology equipment) level "B". Input
mains harmonics as per EN61000-3-2.
Care must be taken when designing the shelf and rack wiring to ensure continued compliance of rectifiers with
the above regulations. It is recommended that live, neutral and earth input wires are run together; also that
positive and negative output busses are run adjacent. This reduces the likelihood of inadvertently creating loop
antennas in the wiring. Experience shows that signal leads can radiate EMC, and it is recommended that all
signal leads be screened.
Additional filters in input or output power circuits should be used with care as resonances introduced can
worsen the EMC performance of the rectifier(s).
The equipment has been carefully inspected and submitted to comprehensive test at the factory prior to
despatch. If, within the warranty period, any defect is discovered in the equipment in respect of material or
workmanship and reasonably within our control, we undertake to make good the defect at our own expense
subject to the standard conditions of sale. In exceptional circumstances and at the discretion of the Service
Manager, a charge for labour and carriage costs incurred may be made.
Our responsibility is in all cases limited to the cost of making good the defect in the equipment itself. The
guarantee does not extend to third parties, nor does it apply to defects caused by abnormal conditions of
working, accident, misuse, neglect or wear and tear.
In the event of difficulty or apparent malfunction it is recommended that you contact the Service Department or
your local Sales Engineer or Agent (if overseas) in the first instance. If a rectifier needs service, we recommend
that it be returned to the Service Department at the address below, or to your local agent if overseas.
Please ensure adequate care is taken with packing and arrange insurance cover against loss or damage in
transit.
If repairs are to be attempted by the customer these should be undertaken by competent personnel conversant
with switch mode power supply technology.
WARNING Hazardous voltages exist at many points within the equipment: test before touching.