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MPC 1250 Operator'S Manual Download Page 27

006-0007207 MPC-1250DC Guide  

Rev F 

27 of 44

 03/03/2022 

 

www.synqor.com

Section IV 

Constant Current Model

Overview

The MPC‑1250 Family offers a model designed to charge lead‑acid batteries used in 28 V vehicle 

power applications.  This model acts as a current source when overloaded, rather than going 

into a hiccup mode like the other MPC‑1250 models.  Hiccup mode allows other MPC‑1250 

models to deliver higher peak power, while constant current mode allows for battery charging.  

The Constant Current model is designed to be connected directly to the terminals of a lead‑acid 

battery.  It will use the battery to ride through AC/DC source switch overs, and through load 

transients.  The Constant Current model may shut down during these transients if a battery is 

not connected.

Lead‑acid  batteries  use  a  Constant  Current  Constant  Voltage  charging  profile  (CCCV).    The 

MPC‑1250/C model has the following features to facilitate CCCV charging for a variety of different 

lead‑acid batteries:
• Fixed 47 A charging current
• User adjustable nominal output voltage (Vset).  Range is 22‑33 V
• User adjustable “top off” voltage (Vtop).  Range is Vset – 33 V
• User adjustable “top off” time (Ttop).  Range is 0‑ 48 hours

User Settable Parameters – CCCV charging

Constant Current Constant Voltage Charging Overview

Lead‑acid batteries charge with a Constant Current Constant Voltage charging profile, as shown 

in the figure below. 

47A

Vset

Vtop

Ttop

Voltage

Stage 1:

Stage 2:

Stage 3:

Charge Complete

Summary of Contents for 1250

Page 1: ...SHALLOW RACK MOUNT Made in USA Military Power Conditioner MPC 1250 1S Operator s Guide MPC 1250 DC Output Series ...

Page 2: ...opology 7 Part Numbering Scheme and Options 8 Electrical Characteristics 9 Product Specifications 10 MPC 1250 1S 1U Mechanical Diagram 11 MPC Efficiency 12 Total Output Power that can be derived from the AC INPUT 13 Power Cable Wiring Diagram 15 Power Cable Wire Size 16 Section III Operation Set Up 18 Start Up 19 Shut Down 19 Power Cable Connections Disconnections While Operating 20 Cooling System...

Page 3: ...owered 31 Reverse Polarity Protection 31 Section V Multiple MPC Configurations Parallel Connection of DC OUTPUTS Parallel Option 32 N M Redundancy Ideal Diode 32 Configuration Cables 33 On Off control Parallel Systems 33 Section VI Control Interface Details Control Cable Connections 34 Internal User I O Circuits 35 Remote On Off Switch Connections 35 Digital Input Output Control Signals 36 RS232 S...

Page 4: ...er before disconnecting it from the MPC If the AC input cable is connected to the source of AC power and not connected to the MPC do not contact the exposed terminals of the AC input cable Do not assume that the source of AC power is not present Connections between the AC input cable and the source of AC power should not be accessible For the DC INPUT cable and connector The rated DC input voltage...

Page 5: ... chambers 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 MPC or the fan exhausts in the rear panel of the MPC while the MPC is operating User Servi...

Page 6: ...Constant Current model is designed to charge lead acid batteries used in 28 V vehicle power applications The electronic circuitry within the MPC 1250 DC Output 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 w...

Page 7: ...er sources the AC INPUT or the DC INPUT with that order of priority based on availability EMI filters are present at all external inputs and outputs AC INPUT DC INPUT DC OUTPUT AC to DC w PFC and ISOLATION ELECTRONIC SWITCH ISOLATED DC DC CONVERTER BULK ENERGY STORAGE CAPACITOR IDEAL DIODE Power flows from the AC INPUT through an AC DC converter that has Power Factor Correction PFC and high freque...

Page 8: ...Options E Ethernet SNMP with Configuration Loading 00 No CE Marking Examples CE CE Marking MPC 1250 1S LR28D00 E00 MPC 1250 1S WP24D00 E00 MPC 1250 1S LR28D00 ECE Fully Regulated with CE Marking Select 28 V Output option when ordering Constant Current regulation type The MPC 1250 DC Output Series of products provide up to 1250 W of total output power DC Various options can be specified according t...

Page 9: ... kHz RS103 2 MHz 40 GHz Regarding MIL STD 461 CE 101 the 50 uH series inductance of a standard LISN adversely affects the input ripple of the MPC DC input only Such a large series source inductance 50 uH in each power lead is not generally encountered in a 28 V DC source of such high power rating Therefore testing for CE 101 DC input was conducted with 3 different configurations two using 50 uH LI...

Page 10: ...hese specifications and other information can be found at the web site http www synqor com MPC MPC 1250 1S with AC DC Input DC Output MPC 1250 1S MPC 1250 1S With Constant Current Output On Off Switch On Off Switch DC Output Fan Exhaust DC Input Fan Exhaust AC Circuit Breaker AC Input Status LED Status LED Status Indication Panel Status Indication Panel External Battery Voltage 1 73 1U 17 00 Air i...

Page 11: ...ct Information 006 0007207 MPC 1250DC Guide Rev F 11 of 44 03 03 2022 www synqor com MPC 1250 1S 1U Mechanical Diagram MILITARY POWER CONDITIONER S T A T U S MPC 1 73 1 50 17 00 14 80 14 00 750 750 750 11 750 0 55 0 313 0 625 ...

Page 12: ...C OUTPUT from a 22 28 and 33 volts input 80 82 84 86 88 90 92 94 0 250 500 750 1000 1250 Efficiency Output Power W Efficiency vs Output Power 28 V 33 V 22 V Figure 1 Figure 2 shows the typical efficiency with which the MPC 1250 DC Output Series uninterruptible power supplies delivers power to its DC OUTPUT from 115 VAC and 230 VAC input 70 72 74 76 78 80 82 84 86 0 250 500 750 1000 1250 Efficiency Outpu...

Page 13: ...0 W at 80 Vrms 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 1125 W at 85 Vrms as long as the ambient temperature is not above 50o C 122o F If the total output power is greater than this derated value the MPC will switch to the DC INPUT if it is available and 22 V If the AC INPUT voltage is ...

Page 14: ...Figure 3 Note that the full rated output power of 1250 W can be derived from the AC INPUT having a voltage within this uncommon range for 15 seconds before the MPC will switch over to the DC INPUT Also note that the MPC can drive it full rated power for a 2 second interval even if the AC INPUT voltage drops below 90 Vrms 0 200 400 600 800 1000 1200 1400 25 30 35 40 45 50 55 Air Temperature C MPC O...

Page 15: ...gram Looking at the rear panel the MPC connector terminals have the following functions and locations AC INPUT Pin Function A Line B Neutral C No Connect D Ground A B D C DC INPUT Pin Function G F E Vin B C D Vin Return A H No Connect A B C D E F G H DC OUTPUT Pin Function G F E VOUT B C D VOUT Return A H No Connect A H F C B G D E ...

Page 16: ...oltage across the cable at its downstream end is smaller than the voltage across the cable at its upstream end Mathematically the amount that the voltage drops is equal to the resistance of the cable s wire multiplied by the current flowing through the wire It is therefore important to make sure that the resistance of the cable s wire is small enough to keep this voltage drop to an acceptably smal...

Page 17: ...ediameter This second approach gives a more flexible cable For 10 ft long cables SynQor recommends that for the MPC 1250 DC Output Series The AC INPUT cable has 3 wires one for the ground of 12 AWG The DC INPUT cable has 6 wires three for each connection of 12 AWG The DC OUTPUT cable has 6 wires three for each connection of 12 AWG Additional details about the effects of a resistance related voltag...

Page 18: ... USER I O cables Connect all INPUT cables first to the MPC and then to the various sources An overcurrent protect and disconnect device should be installed on the DC INPUT circuit An example of a suitable device is a Carling Technologies C series 80 A 65 VDC CA1 B0 14 680 321 J circuit breaker www carlingtech com VERIFY that the DC INPUT cable is connected to the MPC and the source of DC power wit...

Page 19: ...ove the ON OFF switch will change to green The LEDs on the front panel will indicate the amount of power being delivered to the load and the input source from which this power is being drawn Shut Down Shut down the equipment connected to the MPC Push the ON OFF switch on the front panel of the MPC downward and hold it in this position for 1 second or more The color of the LED above the ON OFF swit...

Page 20: ...out harming the MPC or disrupting power delivery to a load that might be connected to the other output NOTE that disconnecting an input or output power cable while that cable is handling power will likely cause an arc to form as the terminals are pulled apart This arcing is not harmful to the MPC although if done enough times it will degrade the connector to the point where it will need to be repl...

Page 21: ... such that the MPC 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 There is an LED on the front panel that indicates the speed of the fans 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...

Page 22: ...his section LEDs LED above the ON OFF switch This LED has four possible indications according to the table below LED Appearance Description Indication Green MPC is Running Outputs are Enabled Amber MPC is on Standby Outputs are Enabled Red MPC has a Fault Condition Off MPC is Off LEDs on the Front Panel Regulated and Parallel Models The Regulated and Parallel models each have a 10 LED front panel ...

Page 23: ...dicates the status of the AC INPUT according to the table below LED Appearance Description Indication Green Input is Ready to Provide Load Power Pulsing Green Input is the One Presently Selected as the Source of Power Amber Input has Returned within Range and Diagnostic Tests are Being Performed Off Input is Not within Range Power Out Indicator LED in position A0 The LED in position A0 indicates t...

Page 24: ...ED in position F0 indicates the temperature and status of the cooling system for the MPC according to the table below LED Appearance Description Indication Green Moderate MPC Temperature Fans Running at 33 Blinking Green Warm MPC Temperature Fans Running at 67 Amber Elevated MPC Temperature Fans Running at 100 Red Maximum MPC Temperature Fans Running at 110 Fan Service Required Indicator LED in po...

Page 25: ... Output Voltage E0 Green E1 Dimmed Green E2 E3 Off E0 E1 Green E2 Dimmed Green E3 Off E0 E1 E2 Green E3 Dimmed Green E0 E1 E2 E3 Green Vout Vset Audible alarm For critical situations a pattern of audible tones will be repeated every 5 seconds according to the table below This audible alarm can be silenced by holding the ON OFF switch on the front panel in the UP position until a chirp is heard A n...

Page 26: ...and III 15 000 ft operating 40 000 ft storage 501 5 High Temperature I and II 55o C operating 65o C storage 502 5 Low Temperature I and II 20o C operating 40o C storage 503 5 Temperature Shock I 10 cycles 10o C minute 506 5 Rain I 4 rain hour 40 mph wind velocity 507 5 Humidity NA 95 508 6 Fungus NA 28 day test 509 5 Salt Fog NA 5 salt solution 2 cycles 24 hr wet 24 hr dry 510 5 Sand and Dust I an...

Page 27: ...DC source switch overs and through load transients The Constant Current model may shut down during these transients if a battery is not connected Lead acid batteries use a Constant Current Constant Voltage charging profile CCCV The MPC 1250 C model has the following features to facilitate CCCV charging for a variety of different lead acid batteries Fixed 47 A charging current User adjustable nomin...

Page 28: ...ases slowly until the top off time expires The MPC 1250 default top off time is 8 hours Once the user settable top off Ttop time has expired the MPC transitions to phase III In phase III the MPC is in normal operation The output voltage is lowered to the user adjustable nominal value Vset The default value for Vset is 28 V Setting CCCV parameters The CCCV parameters discussed in the previous secti...

Page 29: ...ttingdown Externalbreakersarenot requiredto protect the MPC however an external breaker may be necessary to protect end use equipment Low current loads with wires not sized for 47 A should be protected by a breaker or fuse In addition to the 47 A current limit the MPC 1250 for CCCV charging has an Over Power limit When Vset or Vtop are set above 27 V the MPC is capable of delivering more than 1250...

Page 30: ...age reaches Vset The MPC exits CCCV charge mode when the voltage has recovered to Vtop and Ttop has expired Stage II has completed To end Stage II early the user can set Ttop to a lower value Over Power protection will not cause the MPC to enter CCCV charge mode Visual indicators External Battery Charge Level LEDs E0 E3 are unique to the Constant Current MPC 1250 model These LEDs provide a rough e...

Page 31: ... is not enabled the vampire current increases to 250 450 µA depending on the output voltage The MPC 1250 output should be enabled periodically to keep the battery charged when input power is available Reverse Polarity Protection The Constant Current model provides reverse polarity protection on the DC output This prevents catastrophic damage in the event the output is connected to the battery term...

Page 32: ...Paralleling C MPC 1250 1S 1U LC28D00 E00 N M Redundancy Ideal Diode The ideal diode on the DC OUTPUT provides N M redundancy when multiple units are placed in parallel An N M redundant system consists of N units to supply the maximum load and M additional units to provide redundancy Typically one additional unit is used for redundancy giving N 1 redundancy During normal operation all N M units wil...

Page 33: ... SYN 9344 5 units parallel 12 SYN 9345 On Off control Parallel Systems When several units are connected in parallel any on front panel switch actuation will cause all outputs to turn on at once In addition the remote on rear panel signal can be used for a coordinated start Any off front panel switch actuation will cause that specific unit be turned off All other units will continue to deliver powe...

Page 34: ... the MPC The User I O female DB15 connector on the left is for a connection to a host system computer so that it can control the MPC and receive information regarding the status of the MPC The Configuration male DB15 connector on the right is used to connect multiple MPCs in parallel See Section IV for details The designation location of the pins for the User I O female high density DB15 connector...

Page 35: ...4148 2N3904 Input Pin 50k Ohms 100 Ohms 5V 500 Ohms PS2581L 1N4148 I O Circuits OUTPUT ON OUTPUT OFF 5V Pin SHUTDOWN Input Pin Remote On Off Switch SPDT Momentary ON OFF ON 100 Ohms 5V 8 500 Ohms 13 PS2581L 1N4148 REMOTE_START Input Pin 500 Ohms 12 PS2581L 1N4148 Internal User I O Circuits Remote On Off Switch Connections Note A 2PDT or 3PDT switch may be substituted for single control of 2 or 3 M...

Page 36: ...here low indicates that the MPC is at or above its maximum temperature REMOTE_START 12 Drive this line high with 5mA to enable the MPC outputs SHUTDOWN 13 Drive this line high with 5mA to disable the MPC outputs with an internal 50 kΩ Pull up Resistor to 5 V and ESD Protection Diodes RS232 Serial Interface The same User I O female high density DB15 connector also provides for an RS232 interface be...

Page 37: ...ace for monitoring and control of the MPC The user can configure email alerts for MPC 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 RJ 45 connector also allowing a metallic sealable circular military outer housing The interface supports auto negotiation polarity correction ...

Page 38: ...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 tak...

Page 39: ...s that could cause the MPC to not operate as desired These external conditions can likely be corrected by the user The 10 LEDs on the front panel are the best and first place to look to determine what might be wrong with the MPC 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...

Page 40: ... INPUT cable is connected to the DC source with the wrong polarity The DC INPUT voltage is either too low or too high The DC INPUT cable may have too much series resistance Thicker wire should be used A0 DC OUTPUT Power LED LED is OFF The MPC is OFF and needs to be turned ON LED is AMBER The DC Output load is higher than 1250 W The DC Output is shorted within the cable or a load Some other source ...

Page 41: ...ver temperature shut down circuitry C0 Fan Service Required LED LED is AMBER One or both fans have recently had degraded performance but seem to be ok now The MPC is running a diagnostic test LED is RED 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 A...

Page 42: ...onnected to the DC OUTPUT of a MPC 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 The MPC fails to start the load The SynQor MPC is designed to overcome the problem of surge currents with some loads If there is more than one load of the DC OUTPU...

Page 43: ...o draw current from the DC INPUT cable This current causes a voltage drop to appear across the cable If the voltage at the DC source is close to but still above its 22 V minimum but the voltage drop across the cable is large enough for the voltage at the DC INPUT of the MPC to fall below 22 V then the MPC will determine that the DC INPUT is out of range and will shutdown Since the MPC no longer dr...

Page 44: ...y Power Conditioner 006 0007207 03 03 2022 Rev F 1 888 567 9596 USA only SynQor Headquarters 155 Swanson Road Boxborough MA 01719 1316 USA www synqor com Made in USA Operator s Guide MPC 1250 DC Output Series ...

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