Unipower Aspiro 1U, XPGe12.48, XR08.48, XR04.48 Instruction Manual

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POWERING TECHNOLOGY

Power Supply System

Aspiro 1U

Instruction Manual

Document Number: M00035-MAN rev. 3a

www.unipowerco.com

UNIPOWER LLC • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • sales@unipowerco.com

North America: +1 954-346-2442 • Latin America: +1 954-905-1078 • Europe: +44 1903 768200

POWERING TECHNOLOGY

Restricted Rights Legend:

Use, duplication, or disclosure by the Government is subject to restrictions as set forth in subparagraph © (1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS

252.227-7013 or subparagraphs © (1) and (2) of Commercial Computer Software - Restricted Rights at 48 CFR 52.227-19, as applicable.

For Contact Information, please go to http://www.unipowerco.com/contact/

Refer to the UNIPOWER License Agreement in this package before installing or using this product.

Unless specically noted, all addresses, data characters and persons referenced herein, and all examples involving names of companies and products, are ctitious examples and are designed

solely to illustrate the use of UNIPOWER products.

Product names, logos, brands, and other trademarks featured or referred to within this product manual are the property of their respective trademark holders. These trademark holders are not

aliated with UNIPOWER LLC or our products. They do not sponsor or endorse our products.

LIMITATIONS AND AUTHORIZATIONS FOR USE AND PERMITTED APPLICATIONS

UNIPOWER’s products are not designed, intended for use in, or authorized for use as critical components in, human life support systems/equipment, equipment used in hazardous environments, or equipment used in nuclear control equipment or systems. Any such use requires the prior

express written consent of an authorized executive ocer of UNIPOWER LLC, which consent

may be withheld by UNIPOWER LLC in its sole discretion. Users assume all risk and liability for, and agree to indemnify and defend UNIPOWER from and against any claims for personal injury (including death) or property damage resulting from any such use or application which is made in the absence of such prior express written consent.

If you nd errors or problems with this documentation, please notify UNIPOWER. UNIPOWER

does not guarantee that this document is error-free. The information in this document is subject to change without notice.

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Contents

Chapter 1 About This Manual

1.1 Objectives ..................................................................................................................................6

1.2 Audience ....................................................................................................................................6

1.3 Document Key ...........................................................................................................................6

1.4 Feedback & Support ..................................................................................................................7

1.6 Disclaimer ..................................................................................................................................7

Chapter 2 Aspiro System Description

2.1 Overview ....................................................................................................................................8

2.2 System Congurations ...............................................................................................................8

2.3 System Parameters .....................................................................................................................9

2.4 System Components.................................................................................................................11

2.4.1 System Controller ...........................................................................................................11

2.4.2 DC Distribution ...............................................................................................................11

2.4.4 Rectier Module .............................................................................................................12

Chapter 3 System Safety

3.1 Safety Warnings and Guidelines ..............................................................................................13

3.1.1 System Markings ............................................................................................................13

3.1.2 Safety Recommendations ................................................................................................13

3.1.3 Installation Warning ........................................................................................................14

3.1.4 Restricted Access Area Warnings....................................................................................14

3.1.5 Electrical and Fire Enclosure ..........................................................................................14

3.1.6 System Enclosure ............................................................................................................14

3.1.7 Operating Temperature Warnings ...................................................................................14

3.1.8 Electrical Safety Warnings ..............................................................................................14

3.1.9 Grounding .......................................................................................................................15

3.1.10 Batteries ........................................................................................................................16

3.1.10.1 Lead Acid Batteries ........................................................................................16

3.1.11 In Case of an Accident ..................................................................................................16

3.2 Caution .....................................................................................................................................17

3.2.1 Storage and Transportation .............................................................................................17

3.2.2 Disposal...........................................................................................................................17

3.2.3 Handling Electrostatic Sensitive Devices .......................................................................17

3.2.4 Traceability .....................................................................................................................17

3.2.5 Breakers ..........................................................................................................................17

3.2.5.1 Circuit Breaker Limitations .............................................................................17

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Chapter 4 Installation Guide

4.1 Introduction ..............................................................................................................................19

4.2 Unpacking ................................................................................................................................19

4.3 Tools 19

4.4 Rack Mounting .........................................................................................................................19

4.5 Rear Connections .....................................................................................................................21

4.5.1 DC Earth Connection (FRAME GROUND) ..................................................................21

4.5.2 Mains Connection ...........................................................................................................22

4.5.3 Alarm and Signal Connections ........................................................................................23

4.5.4 DC Load Connections .....................................................................................................25

4.5.5 Battery Connections .......................................................................................................26

4.5.6 Symmetry Connection ....................................................................................................27

4.5.7 Temperature Sensor Connection .....................................................................................28

Chapter 5 Commissioning

5.1 Commissioning Overview .......................................................................................................29

5.2 Tools and Test Equipment ........................................................................................................29

5.2.1 Tools List .........................................................................................................................29

5.2.2 Test Equipment ...............................................................................................................29

5.3 Preparation ...............................................................................................................................29

5.4 Commissioning procedure .......................................................................................................30

5.5 Test of output voltage ...............................................................................................................31

5.5.1 Float charge (U1) ............................................................................................................31

5.5.2 Adjustment of Float Charge, U1 .....................................................................................31

5.5.3 Boost charging (U2) (if applicable) ................................................................................31

5.6 Battery supervision ..................................................................................................................32

5.7 Battery test ...............................................................................................................................32

5.8 Commissioning record .............................................................................................................33

Chapter 6 Maintenance & Troubleshooting

6.1 Maintenance .............................................................................................................................34

6.2 Troubleshooting .......................................................................................................................34

Chapter 7 Replacing Modules

7.1 Controller Replacement ...........................................................................................................38

7.2 Rectier Replacement ..............................................................................................................39

7.2.1 XR04.48 / XR08.48 Replacement ..................................................................................39

7.2.2 XPGe12.48 Replacement ................................................................................................39

7.3 Breaker Replacement ...............................................................................................................40

Appendix A - Block Diagram ......................................................................................................42

Appendix B - CSA Certicate Extract .......................................................................................43

Appendix C - Revision History ...................................................................................................44

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FIGURES

Figure 2-1 Power System Overview ...........................................................................................8

Figure 2-2 XPGe12.48 and XR04.48/XR08.48 ........................................................................12

Figure 4-1 Dimensional Drawing (Front and Top View) ..........................................................20

Figure 4-2 System Mounting (19” mount) ................................................................................20

Figure 4-3 Rear Connections .....................................................................................................21

Figure 4-4 DC Earth Connections .............................................................................................21

Figure 4-5 Mains Connection (viewed from rear) .....................................................................22

Figure 4-6 Mains Connection Detail .........................................................................................23

Figure 4-7 Signal Pin Designations ...........................................................................................24

Figure 4-8 Signal Connection Detail .........................................................................................25

Figure 4-9 Load and Battery Connections (Rear View) ............................................................25

Figure 4-10 Signal Connection Detail .........................................................................................26

Figure 4-11 2-block Symmetry Measurement (for illustration only) ..........................................27

Figure 4-12 4-Block Symmetry Measurement (for illustration only) .........................................27

Figure 4-13 Temperature Sensor Connection ..............................................................................28

Figure 7-1 Unlocking the Controller .........................................................................................38

Figure 7-2 Removing the Controller .........................................................................................38

Figure 7-3 Replacing an XR04.48 or XR08.48 Rectier ..........................................................39

Figure 7-3 Replacing an XPGe12.48 Rectier ..........................................................................40

Figure 7-5 Top Cover Removal .................................................................................................40

Figure 7-6 Breaker Removal - A ...............................................................................................41

Figure 7-7 Breaker Removal - B ...............................................................................................41

TABLES

Table 4-1 Recommended Mains Circuit Protection .................................................................22

Table 4-2 Cable Sizes ..............................................................................................................26

Table 4-3 Cable Sizes ..............................................................................................................27

Table 5-1 Float/Boost Charge Voltages ...................................................................................31

Table 5-2 Commissioning Record ...........................................................................................33

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Chapter 1 About This Manual

1. About This Manual

This chapter contains an overview of the information that is presented in this Power System Manual. This includes information on objectives, the intended audience, and the organization

of this manual. In addition, this chapter also denes the conventions used to indicate warnings,

cautions and noteworthy information.

1.1 Objectives

This manual describes the Power System, explains how to unpack and install the system, how to perform the initial power-up and operational system check.

The information presented in this document is current as of the publication date.

1.2 Audience

This manual is to be used by installers and technicians who are preparing the site for a new installation and installing the power system. This manual assumes that the technician has an understanding of power systems in general and understands safety procedures for working around AC and DC voltage.

The user of this document should be familiar with electronic circuitry and wiring practices and have some expertise as an electronic, power, or electromechanical technician.

1.3 Document Key

This manual uses the following conventions:

WARNING This symbol indicates a situation that could cause bodily injury. Always be aware of hazardous conditions when working in or around the power system.

CAUTION This symbol indicates a situation that might result in equipment damage. The reader should be aware that their actions could result in equipment or data loss.

NEED MORE INFORMATION? This symbol is used to reference information either in this manual or in another document.

NOTE This symbol means the reader should take note. Notes are helpful suggestions or reminders.

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Table 1-1 Abbreviations

Abbreviation Description

PCC Prime Controller Card

ACC Advance Controller Card

LVD Low Voltage Disconnection

PLD Partial Load Disconnection

XR04.48 400 W Rectier

XR08.48 800 W Rectier

XPGe12.48 1200 W Rectier

DB22 Distribution Drawer (4 x load, 1 x battery)

D22 Distribution Drawer (3 x load)

D33 Distribution Drawer 2 x load)

B33 Distribution Drawer (2 x battery)

1.4 Feedback & Support

For technical support or feedback, please visit http://www.unipowerco.com/contact/ for details.

Alternatively, email: technical.support.repair@unipowerco.com

1.5 Layout, Numbering and Printing

This manual is intended for two-sided black and white printing. Some pages are intentionally left blank.

1.6 Disclaimer

UNIPOWER is not responsible for system problems that are the result of installation or

modication of the instructions provided in this manual.

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Chapter 2 Aspiro System Description

2.1 Overview

Aspiro DC power systems oer a range of solutions for diverse applications such as broadband

access, cable head ends, micro/pico BTS Cells, Enterprise, E911, and GSM-R.

The Aspiro shelf system utilizes ecient, dense, and reliable plug-in rectier modules

XR04.48, XR08.48 or XPGe12.48, with output power available at either 400W, 800W or

1200W per rectier, based upon a soft-switching approach. Features include wide input

operating range, wide operating temperature, full self-protection and three LEDs for

immediate rectier status indication.

The power system can be managed locally through messages and alarm displayed on the LCD screen of the system controller or remotely, using the PC-based PowCom™ software, or through a web browser with Ethernet connection.

2.2 System Congurations

Aspiro 1U system consists of:

1. System Controller ACC Extended

2. 4 x Load and 1 x Battery breakers including LVD

3. XR04.48 / XR08.48 / XPGe12.48 Rectiers (Maximum 2)

4. Rear Connections

Document No. M00035-MAN rev. 3a

Figure 2-1 Power System Overview

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POWERING TECHNOLOGY

2.3 System Parameters

OUTPUT

Power (max) 2400W @ >180VAC, 800W @ <180VAC

Output Current 52A max. @ 46VDC, 45A nominal (see appendix B)

15A (Low Power Shelf version with 20A shunt)

Voltage 46-57VDC

INPUT

Voltage 85-275VAC (Single-phase, 2 x Single-phase)

Frequency 50-60Hz

Input Current 16A (Single-phase), 8A (2 x Single-phase)

Power factor >0.98

DC DISTRIBUTION

Battery Breakers 1 x (AIRPAX, IER Series)

Ratings 40A, 50A, 65A

Load Breakers 4 x (NADER NDB3 Series)

Ratings* 1A, 4A, 5A, 7.5A, 10A, 15A, 20A, 25A, 30A

MONITORING AND CONTROL

Controller PCC or ACC Extended

Local Interface 4 x 20’ LCD, 4-key menu, USB (ACC only) and RS232

Remote Interface Ethernet / Modem using PowCom™ software

Visual Indication Green LED - System On

Yellow LED - Message(s) Red LED - Alarm(s)

Analog Inputs 12 x voltage inputs (range 0-100VDC) - used for symmetry inputs

Analog Outputs 4 x potential free relays (C, NC, NO)

Digital Inputs 2 x, Logic 0: U<10VDC, Logic 1: U>12VDC

Digital Outputs 2 x, open collector type

Temperature measurement 2 x Temperature probe (Battery, Ambient)

CONNECTIONS

Battery connections Stripped cable, max.16mm2, spring type connector

AC connections Stripped cable with ferule, max. 2.5mm2, screw type connector

Load breaker connections Stripped cable with ferule, max. 4mm2, screw type connector

Alarm connections Stripped cable with ferule, max. 1.5mm2, screw type connector

* For load breaker derating limitations see chapter 3.2.5 Breakers on page 3-6.

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RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48

E󰀩ciency 95% typical @ I

nom 90% typical @ I

out

nom 88% typical @ I

out

nom

Input Current (max) <7.3A <10.5A <5.3A

Output Current (max)

22.4A 15.0A 7.5A

53.5V oat

Output Power 1200W @ >180VAC

800W 400W

750W @ 90-180VAC

Operating Temperature

55°C 65°C 65°C

(without derating)

Input Voltage

90-300VAC 85-300VAC

(Nominal 100-240VAC)

Output Voltage 46-57VDC

Load sharing < 5% of nominal current

Dimensions (WxHxD) 40.6 (1.6”) x 101.62(4”) x 228.5(9”) mm

Weight 1.1 kg

Cooling Fan-cooled, speed and alarm controlled, air ow direction rear to front

Protection Short circuit proof, automatic current limiting, selective shutdown of modules at

excessive output voltage.

Alarms High output voltage/ shutdown, Low voltage/ module failure

LED Indication Green: Power ON

Yellow: Current limit/ thermal protection Fan failure / Over temperature Pre-warning / thermal protection

Communication Failure (ashing)

Red: Module failure / high output voltage shutdown

Audible noise <55dBA according to ISO7779

MECHANICAL

Dimensions (WxHxD) 480 mm x 44.45 mm x 266 mm

Weight of the system

6.5 kg

(fully equipped)

Mounting Options 19”/ ETSI / Mid-mount

Cable Entry Rear Access

STANDARD COMPLIANCE / ENVIRONMENTAL

EMC and Immunity ETSI EN 300 386 V.1.5

EN 55022 EN 55024, EN 61000-4

Safety EN 60950-1

Operating Temperature -40°C to +75°C, derating over +47°C (see appendix B)

Storage Temperature -40°C to +85°C

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2.4 System Components

The Aspiro system is delivered with all components mounted according to the ordered

conguration. The main components are described below and in later chapters of the manual.

There are 2 versions of Aspiro shelf available depending on the value of battery current shunt used: 20 A or 80 A.

CAUTION Low Power Shelf version (20 A version) provides better resolution for battery current reading and it is suitable for low power applications with maximum battery charge current less than 5A.

2.4.1 System Controller

The Aspiro power system can be controlled by the ACC Extended or PCC controller. The description and operation of these controllers is covered in separate manuals which are available at:

ACC Extended: http://www.unipowerco.com/pdf/acc-man.pdf

PCC: http://www.unipowerco.com/pdf/pcc-man.pdf

2.4.2 DC Distribution

DC Distribution consists of maximum 1 battery and 4 load breakers available in a variety of sizes.

The distribution unit is designed for switching the battery and load on and o.

The battery and load breakers are supervised by measuring the voltage drop across each breaker. In the case of load breakers, those which are not connected to any load will not cause a breaker alarm even if they are left open.

A battery fuse alarm is generated after the battery voltage drops below a certain level, depending on the actual battery capacity and condition.

Low Voltage Disconnect (LVD)

The system is equipped with a low voltage battery disconnect which prevents the batteries from deep discharging, thus prolonging the battery life. The disconnect requires a detected mains failure at the supervision unit (controller).

If disconnection occurs, the batteries will not supply power to the load until they have been recharged to a set voltage level, which can be adjusted by the user.

If disconnection occurs, the batteries will be reconnected when the mains supply returns.

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2.4.4 Rectier Module

The Fan-Cooled XPGe12.48 (1200W), XR08.48 (800W) and XR04.48 (400W) rectiers

are modular power supplies designed for parallel operation and hot-plug installation in the Aspiro Power Systems.

Each rectier provides extremely reliable DC power in a very high density. The module

incorporates power monitoring through an internal microprocessor, giving up to the

second updates to the system controller and companion rectiers. This guarantees tightly controlled load sharing among rectiers, and provides status and identication

information to the controller.

The rectiers operate in parallel using active load sharing. They incorporate soft-start

at both the input and the output, which protects against high incoming and outgoing

currents. The output voltage of the rectier is automatically adjusted to the required

voltage by the controller.

XPGe12.48 rectiers cannot be used in the same rack as XR04.48 / XR08.48 rectiers.

CAUTION XPGe12.48 rectiers cannot be used in the same system as XR04.48/ XR08.48 rectiers.

Document No. M00035-MAN rev. 3a

Figure 2-2 XPGe12.48 and XR04.48/XR08.48

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Chapter 3 System Safety

3.1 Safety Warnings and Guidelines

The following warnings and guidelines should be followed by properly trained and authorized personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the instructions may be dangerous to personnel and equipment.

3.1.1 System Markings

The following markings are found on the Power System:

Ground Symbol

DC Ground Symbol

Product Label - The product label contains the system part number, model number, system

ratings and safety approvals. The label is located on the left side of top cover.

3.1.2 Safety Recommendations

Any device that uses electricity requires proper guidelines to ensure safety.

• The Power System should only be installed or serviced by a qualied personnel.

• Always keep tools away from walkways and aisles. Tools present a tripping hazard

in conned areas.

• Keep the system area clear and dust-free during and after the installation.

• Always know the location of emergency shut-o switches in case of an accident.

• Always wear appropriate eye protection and use appropriate tools for working with high voltage equipment.

• Do not perform any action that creates a potential hazard to other people in the system area.

• Never work alone in potentially hazardous conditions.

• Always check for possible hazards before beginning work.

• Remove watches, rings and jewelry that may present a hazard while working on the power system.

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3.1.3 Installation Warning

The following safety guidelines should be observed when transporting or moving the system:

• Before moving the Power System, read the system specications sheet to determine whether the install site meets all the size, environmental, and power requirements.

• The system and the equipment included, should only be moved and installed by

qualied personnel to prevent bodily injury or any other hazardous conditions.

3.1.4 Restricted Access Area Warnings

The Power System is designed for installation in locations with restricted access often secured by a locking mechanism. It can therefore be accessed only by a trained service person, who is fully aware of the restrictions applied to the location, or by an authority responsible for the location.

3.1.5 Electrical and Fire Enclosure

The unit is for building-in. A suitable Electrical and Fire enclosure shall be provided.

3.1.6 System Enclosure

Appropriate measures need to be taken to avoid intrusion of any unwanted objects or insects into conductive areas of the power system as there is a potential risk of system damage.

Disclaimer: UNIPOWER LLC assumes no liability or responsibility for system failures resulting from inappropriate enclosure around the system.

3.1.7 Operating Temperature Warnings

To prevent the Power System from overheating, an automatic shutdown mechanism has been installed. It is not recommended to continually operate the Power System in an area that exceeds the maximum recommended operating temperature.

3.1.8 Electrical Safety Warnings

The following are electrical safety recommendations for working near the Power System:

WARNING Observe low voltage safety precautions before attempting to work on the system when power is connected. Potentially lethal voltages are present within the system.

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WARNING Caution must be exercised when handling system power cables. Damage to the insulation or contact points of cables can cause contact with lethal voltages. For safety reasons, cables should be connected to the power system before power is applied.

• Remove all metallic jewelry like watches or rings that may present a hazard while working on the power system.

• Before connecting the AC input source to the power system, always verify voltage.

• Verify the AC source capacity. See system specications for AC information.

• All AC connections must conform to local codes and regulations, e.g. ANSI, CEC, NEC, etc.

• When making AC connections, all AC power and DC load distribution breakers should be in the OFF position.

• All circuit breakers should meet the original design specications of the system. In addition, equipment connected to the system should not overload the circuit breakers

as this may have a negative eect on overcurrent protection and supply wiring, causing

system or user harm.

• Verify the DC capacity before making connections. See system specications for DC information.

• Potentially lethal voltages are present within the system. Ensure that all power supplies are completely isolated by turning all power switches OFF, disconnecting all relevant connectors and removing all relevant breakers before attempting any maintenance work. Do not rely on switches alone to isolate the power supply. Batteries should also be disconnected.

• Potentially lethal voltages are present within this system. Ensure that low voltage safety requirements are implemented before attempting to work on the system with power connected.

• Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly. Ensure that all ground connections are secure.

3.1.9 Grounding

WARNING Grounding connection must be performed before operating the system. Refer to local codes, e.g. ANSI, CEC, NEC, T1-333, ETSI 300-386-TC specifying the connection of power system to building ground. In case of any doubt regarding the grounding connection, please contact a person responsible for the system.

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WARNING The system should be hard-wired to the incoming earth ground. A solid high current ground connection capable of sinking the maximum system current is required.

3.1.10 Batteries

WARNING When installing or replacing batteries, there is risk of explosion if an incorrect battery type is used.

3.1.10.1 Lead Acid Batteries

WARNING This equipment may use Lead Acid Batteries. When handling batteries,

follow the instructions included with the battery set, as the uids contained within these

batteries are known to be a health hazard. The disposal of lead acid batteries is subject to legal requirements for hazardous waste disposal. Local guidelines should be followed for disposal.

Ensure the following guidelines are observed when dealing with equipment that may contain lead acid batteries:

• Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes.

• Should a lead acid battery suer damage, it must be moved into a well-ventilated area.

Contact with the corrosive uid must be avoided.

• Neutralize any acid corrosion with copious amounts of a solution of baking soda and

water, and then wipe o all traces of soda.

• If the lead acid battery is removed from the equipment, any exposed contact must be insulated prior to disposal.

• Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are used when working with the batteries. It is advised also to have water available in case acid gets in contact with the eyes.

3.1.11 In Case of an Accident

In the event of an accident resulting in injury:

1. Use caution and check for hazards in the area.

2. Disconnect power to the system.

3. If possible, send someone to get medical aid. If not, check the condition of the victim and call for help.

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3.2 Caution

3.2.1 Storage and Transportation

CAUTION During storage and transportation, the units must remain in their original packages in order to avoid mechanical damage, maintain tracability, and protect the units against electrostatic discharge.

3.2.2 Disposal

CAUTION The product should not be disposed with other wastes at the end of its working life so as to prevent possible harm to the environment or human health from uncontrolled waste disposal.

3.2.3 Handling Electrostatic Sensitive Devices

CAUTION An electrostatic sensitive device is an electronic component that may be permanently damaged by the discharge of electrostatic charges encountered in routine handling, testing and transportation.

3.2.4 Traceability

CAUTION Units are labeled with permanently attached product identication labels.

The labels are designed to be indelible throughout the life span of the equipment, unless

mistreated. Make sure that the product identication labels are present on the equipment

and are not subjected to unusual wear or mistreatment.

3.2.5 Breakers

CAUTION Breakers should always be replaced with the same type and rating in order to avoid damage to system components.

3.2.5.1 Circuit Breaker Limitations

1. Limitations for ambient temperature up to 47°C, maximum system output current 45 Amps:

Maximum load per circuit breakers rated:1A, 4A, 5A, 7.5A, 10A, 15A, 20A and 25A is 80% of their nominal rate.

Maximum load per circuit breaker rated 30A is 60% of its nominal rate.

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2. Limitations for ambient temperature up to 55°C, maximum system output current 45 Amps:

Maximum load per circuit breakers rated:1 A, 4 A, 5 A, 7.5 A, 10 A, 15 A, 20 A and 25 A is 80% of their nominal rate.

Maximum load per circuit breaker rated 30 A is 60% of its nominal rate.

3. Limitations for ambient temperature up to 75°C, maximum system output current 28 Amps:

Maximum load per circuit breakers rated:1 A, 4 A, 5 A, 7.5 A, 10 A, 15 A, 20 A and 25 A is 30% of their nominal rate.

Maximum load per circuit breaker rated 30 A is 20% of its nominal rate.

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Chapter 4 Installation Guide

WARNING There are potential hazards related to installing this power system. It is important to carefully read and understand the contents of Chapter 3 System Safety before performing system installation.

CAUTION Make sure sucient room is left around the system, enabling optimal air

circulation and thus preventing the system from overheating. Keep vent openings from blocking.

4.1 Introduction

This chapter provides detailed instructions for installing the Aspiro 1U Power System.

4.2 Unpacking

Check that the received equipment is in accordance with the packing list. Ensure that the cabinet and the equipment have not been damaged during transportation.

Report any parts that are damaged, missing or incorrect. If possible, correct the problem before continuing.

4.3 Tools

The following tools are required for a safe installation of the system:

WARNING Use only single-ended, fully insulated tools. Shafts of for example screwdrivers should be insulated.

• Anti-static hand strap.

• Insulated screwdrivers, at, sizes 1, 2 and 3.

• Insulated screwdrivers, pozidrive (cross-slot), sizes 1, 2 and 3.

• Insulated torque spanner (for battery connection).

4.4 Rack Mounting

The power system is designed for rack mounting, and the default bracket is for 19 inch rack width. This bracket can be easily adjusted to 23” or ETSI mounting. See Figure 4-1 below.

The brackets are front mounted but can be moved by the user for center mount rack setup.

There needs to be sucient clearance at the front for rectier installation, and at the rear for connections. When using side mains and DC connectors, sucient space should be allowed

for access in this case.

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0.27 (6.8)

10.49 (266.45)

0.98 (25.0)

1.26 (32.0)

0.98 (25.0)

0.22 (5.6)

18.90 (480.1) [19”]

18.21 (462.6) [19”]

22.21 (564.2) [23”]

22.90 (581.7) [23”]

16.81 (426.9)

7.19 (182.5)

19”

1.25 (31.75)

7.52 (190.95)

23”

1.72

(43.6)

0.98 (25.0)

0.59 (15.0)

0.98 (25.0)

0.55 (14.05)

10.63 (270.0)

10.30 (261.0)

Figure 4-1 Dimensional Drawing (Front and Top View)

Aspiro system can be easily mounted to a rack using the taptite screws to fasten the mounting brackets to the rack as shown in Figure 4-2.

NOTE It is recommended to remove the rectiers before installing the shelf to the cabinet

or rack.

Figure 4-2 System Mounting (19” mount)

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SIGNAL

4.5 Rear Connections

All cable connections for the Aspiro system are available at the rear of the system, see Figure 4-3.

CAUTION Use UL-listed wires with an insulation rating to at least 90°C.

WARNING Before inserting the cable into the connector, remove as little insulation on

the cable as possible, to prevent the stranded conductor to come loose and touch any other conductive parts.

GMT OPTION DETAIL

CONNECTIONS

X9 X10

LOAD

BATTERY CONNECTIONS

FRAME

RS485

Figure 4-3 Rear Connections

4.5.1 DC Earth Connection (FRAME GROUND)

WARNING The power system needs to be properly grounded to the rack or cabinet frame

to ensure its safe and ecient operation.

The Earth Connection (Frame Ground) of the rack is located on the rear as shown in Figure 4-3.

To connect:

1. Loosen the screw (M5).

2. Attach suitably sized cable lug.

3. Tighten the screw with torque 3.5Nm. Recommended cable size is 6 mm2.

Document No. M00035-MAN rev. 3a

Figure 4-4 DC Earth Connections

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CONNECTIONS

4.5.2 Mains Connection

WARNING Ensure that mains input is turned o before connecting. The grounding must be connected to PE terminal as rst.

CAUTION Depending on deployment region with regards to lightning strikes and heavy inductive energy, it is highly recommended to install AC Surge Protection Class C.

The Aspiro system family is available with two options for mains connection:

• Single-phase / Phase to Phase (USA) connection

• 2x Single-phase / Phase to Phase (USA) connection

First, check which mains solution is delivered and then follow the appropriate installation instructions below.

Connectors are situated on the right rear side of the system (Figure 4-3), labeled and

congured as seen in Figure 4-5.

RS485

Shelf Type

(See product label)

Single-phase

AC Input

2 x Single-phase

AC Input

Figure 4-5 Mains Connection (viewed from rear)

Number of

Rectiers

Table 4-1 Recommended Mains Circuit Protection

Imax at

100 VAC

18.6 A

at 100VAC

9.3 A

at 100VAC

XR04.48 XR08.48 XPGe12.48

C25A C32A C32A

2 x C25A 2 x C32A 2 x C32A

Recommended

Mains CB

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To connect:

1. Remove sucient insulation from the cables and insert stripped cables into the appropriate terminal.

2. Tighten the corresponding terminal screw

with a at screwdriver, see Figure 4-6.

Maximum cable size is 2.5mm2. Maximum torque required for tightening the screw is 0.5Nm.

Figure 4-6 Mains Connection Detail

4.5.3 Alarm and Signal Connections

Alarm and Signal connections are positioned on the left rear side of the Power Shelf, see Figure 4-3.

For remote supervision of alarms, there are 4 potential free alarm contacts available. Each

alarm contact represents dierent condition. Multi Purpose Voltage Inputs 1-12 can be recongured as external analog inputs.

The pin description detail for all signal connections is shown in Figure 4-7.

Alarm connections are Form C relays and can be monitored either Normally Closed (NC) or Normally Opened (NO). When the power is OFF NC is closed and when the power is ON NC is open.

NOTE Each alarm contact represents a dierent alarm condition or conditions. These is dened in the controller’s alarm matrix setup.

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Battery

Temp.

Multipurpose 10

Multipurpose 11

Multipurpose 12

Sense

+5V

Ambient

Temp.

Sense

+5V

Alarm 4 - C

Alarm 4 - NC

Alarm 4 - NO

Digital In 1

Digital In 2

Digital Out 1

V Sys.

Digital Out 2

10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18

X10

+V Sys.

11223

Multipurpose 1

Multipurpose 2

Multipurpose 3

Document No. M00035-MAN rev. 3a

Multipurpose 4

Multipurpose 5

Multipurpose 6

Multipurpose 7

Figure 4-7 Signal Pin Designations

Multipurpose 8

Multipurpose 9

Page 24

Alarm 1 - C

Alarm 1 - NC

Alarm 1 - NO

Alarm Condition Shown

C NC NO

Alarm 2 - C

Alarm 2 - NC

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Alarm 2 - NO

Alarm 3 - C

Alarm 3 - NC

Alarm 3 - NO

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F1- F1+ F2- F2+ F3- F3+ F4- F4+

Batt - Batt +

To connect:

1. Release a connector from the terminal using a screwdriver and pull it out.

2. Remove sucient insulation from the cables and insert stripped cables into the appropriate connector. Then tighten the

corresponding terminal screw using a at

screwdriver Figure 4-8.

3. After fastening all the cables, insert the connector back into the terminal block.

Maximum cable size is 1.5mm2. Maximum torque required for tightening the screw is 0.25Nm.

Figure 4-8 Signal Connection Detail

4.5.4 DC Load Connections

Load Connections are available at the rear, with connections labeled corresponding to each load breaker, Figure 4-9.

Figure 4-9 Load and Battery Connections (Rear View)

For DC load connections follow instructions given in Figure 4-6.

Maximum cable size is 4.0mm2. Maximum torque required for tightening the screw is 0.6Nm.

CAUTION For correct electrical polarity of DC loads see connector labels.

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Load

Breaker Size

1A 4A 5A 7.5A 10A 15A 20A 25A 30A

[A]

Wire Size

[mm2/AWG]

1/18 1/18 1/18 1/18 1/18 2.5/14 2.5/14 4/12 4/12

Table 4-2 Cable Sizes

4.5.5 Battery Connections

WARNING Improper handling with batteries can be dangerous. Please read and understand the information in the Safety chapter before connecting batteries.

CAUTION Follow closely the battery manufacturer’s specications regarding the

maximum battery charge current value. If the value is less than 5 A, Low Power Shelf version is required.

WARNING The battery cables should be connected to the shelf as rst, then to the

batteries. If the battery cables are already connected to the batteries disconnect the -48 V cable from the battery at least.

Battery connections are available at the rear of the system adjacent to the load connections, see Figure 4-6.

To connect:

1. Remove sucient insulation from the cable (max. 12mm). Make sure no single stranded wire comes loose and touch any other conductive wire.

2. Insert a at screwdriver into the square opening of the battery connection to release a spring latch.

3. Insert the stripped cable into the appropriate round opening.

4. Connect the other end of the battery cables to the batteries.

Document No. M00035-MAN rev. 3a

Figure 4-10 Signal Connection Detail

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Battery

Breaker Size

40A 50A 65A

[A]

Wire Size

[mm2/AWG]

10/6 10/6 16/4

Table 4-3 Cable Sizes

4.5.6 Symmetry Connection

1. Attach the interblock connection plates between the batteries.

2. Insert a suitably sized cable lug into one pole of the interblock connection plate. Fasten the lugs and plates to individual battery poles.

3. For 2-block battery symmetry measurement x one wire of the symmetry cable to the cable lug in the mid-point of the battery string, see Figure 4-11.

4. For 4-block measurement x the 3 wires (red, green and blue) of the symmetry cable to individual cable lugs. Colour coding of the cables must be respected for proper symmetry measurement see Figure 4-12.

Figure 4-11 2-block Symmetry Measurement (for illustration only)

Figure 4-12 4-Block Symmetry Measurement (for illustration only)

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Temp. Sensor

NOTE The interblock Connection Kit is not delivered with the system.

NOTE Symmetry cable is normally pre-connected to the system, see Figure 4-7.

4.5.7 Temperature Sensor Connection

Temperature Sensor Connection for supervising battery temperature is usually delivered pre-

installed when used. On the occasion that it is tted later it is connected using the three-pin

plug according to the same procedure as for the alarm connections.

The sensor itself should be fastened to the battery after battery installation: Unwind the cable, remove the paper covering the adhesive for the sensor and fasten the sensor to the battery as shown in Figure 4-13.

NOTE Temperature sensor is normally pre connected to the system, see Figure 4-7.

Document No. M00035-MAN rev. 3a

Figure 4-13 Temperature Sensor Connection

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Chapter 5 Commissioning

5.1 Commissioning Overview

Before delivery the system was thoroughly inspected and tested. The following chapter is a guide to the set-up and operation of the control functions of the system.

NOTE Before starting commissioning read the product description for the individual components.

WARNING ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

If there are any diculties in increasing the voltage to alarm level, the alarm level can be

adjusted to a lower level.

5.2 Tools and Test Equipment

5.2.1 Tools List

The essential commissioning tools are listed in the Installation chapter.

5.2.2 Test Equipment

• Multimeter (3½ Digit, 0–1%DC)

• Load resistance, to fully load of two rectiers

5.3 Preparation

Check the installation to ensure the following:

• Grounding: The equipment is correctly grounded. The grounding cable size, color and routing conform to the requirements.

• Power: The incoming mains AC power is available for this site. The site power switch and circuit breakers are clearly labeled. The power cables are correctly terminated.

• The site is clean and safe. Check that the system/cabinet is free of any unwanted objects or insects that may have got in during the installation.

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5.4 Commissioning procedure

1. Remove the covers and check that all connections are made according to the installation

drawing. Verify that all connections are properly tightened with sucient torque.

2. Ensure that load and battery MCB breakers are set to OFF position - ensuring the load and battery strings are connected.

3. Ensure that all rectier modules are removed. If not, remove each one in turn starting from the rightmost position.

4. If the rectier subrack has dip switches for addressing, verify that the dip switches are set correctly.

5. Check the battery polarity with the multimeter (3½ Digit, 0·1% dc). Place the positive lead of the meter to the positive busbar and the negative lead to the battery breaker. The meter must now show a positive voltage. If the voltage is negative, change over the connection of the blue and black battery cables to the batteries.

6. Turn on the AC mains voltage.

7. Measure the AC voltage on the AC terminal block between phases and neutral. The

correct value is approximately 230V. If the value is dierent, check the AC connection.

8. Plug in all rectier modules, starting from the leftmost position. Make sure to fasten the rectiers again. The rectiers will turn on automatically.

9. Set all load breakers into the “1” (ON) position.

10. Verify correct polarity on the battery connection by measuring the voltage drop across the battery breaker(s) (Normally not more than 5V DC).

11. The green LED on the controller should blink for approximately 20 sec.

12. The output voltage will increase slowly to U1 (oat charge voltage).

13. Turn the battery breaker(s) to the “1” (ON) position.

14. If any alarms are present, they should be reset in accordance with the procedure for the installed controller, ACC or PCC.

15. The system should now be without alarms.

16. Attach all the system covers in their correct places.

17. Check that all changes to drawings, if any, have been completed.

18. Clean the site.

19. Fill in the commissioning record (see end of chapter).

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5.5 Test of output voltage

5.5.1 Float charge (U1)

Ensure that the controller is operating.

Connect a load, approx. 50% of total capacity, to the system.

Check the voltage according to the battery manufacturer’s requirements. If the batteries

require a dierent oat charging voltage, adjust the output voltage from the controller. (See

the section for the appropriate controller)

If no change is required, use the following values:

Battery type Float charge Boost charge

Open lead-acid batteries 2.23 V/Cell 2.33 V/Cell Valve regulated lead-acid batteries 2.27 V/Cell -

Table 5-1 Float/Boost Charge Voltages

5.5.2 Adjustment of Float Charge, U1

Unless otherwise ordered the default output voltage is factory pre-set to 53.5V. The total voltage has to be in accordance to the number of battery cells.

Please verify number of cells and the battery manufacturers requirement.

Adjust the output voltage from the control unit as necessary.

NOTE A seal protects the potentiometer in the subrack. Do not break the seal.

5.5.3 Boost charging (U2) (if applicable)

Open lead-acid batteries.

Automatic boost charging - calculation based on the time the battery voltage has been below certain levels. Automatic activating of boost charging for this calculated time multiplied by a (boost) factor.

Activate boost charging from the “Set/select U1-U4” menu in the controller.

Return to oat charge manually by selecting “U1”, or automatically after a pre-set time.

VRLA batteries.

Most of the manufactures of valve regulated lead acid batteries do not recommend boost charging. If this type of battery is used, the boost function should be disabled.

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Boost charging gures

Observe and write down all of the boost charging gures. Parameters to be read/set/adjusted

from control unit or PC with PowCom™ installed.

5.6 Battery supervision

For systems with symmetry cables supplied:

Set the number of battery strings according to the number of battery strings in the system. The settings are to be made in the control unit via a PC with PowCom™ installed or directly in the controller (if symmetry failure is indicated).

The symmetry fault alarm can be simulated by pulling out one symmetry cable from the battery string. Measure that setting to make sure that it is in accordance with the battery manufacturer’s recommendations.

For systems with temp. probe cable supplied:

Temperature compensation is factory pre-set. Check that the temp. probe is activated and verify that the compensation level is in accordance with the battery manufacturer’s requirements. (If no compensation level is available from the battery manufacture, UNIPOWER recommends that it is set to 0.5V).

5.7 Battery test

Settings should be made according to the battery manufacturer’s requirements, but as a rule of thumb the following settings can be used for standard VR lead batteries:

No. of test pr. year = 2

U3 Test = 1,9 V/cell

End voltage b.test = 1,94V/cell

Batt. test time = 40% of expected backup time

Ah limit for test = 40% of nominal battery capacity

Parameters should be set/adjusted from the controller (Battery test menu) or “Supervision Set parameters” menu in PowCom™.

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5.8 Commissioning record

This is a step-by-step commissioning record for easy commissioning of Power Supply Systems. Do not continue if any faults occur during this commissioning. The checkpoints are to be considered as a minimum for commissioning of the system.

1 Check that the rack is level 2 Check that all breakers are turned to “o”

position and that no rectiers are mounted in the

subrack(s).

3 Connect AC, and measure voltage on the mains

input connections in the cabinet, Is to be 230V AC (Measure 230V from phase to N when 400V mains input is used)

4 Mount the rest of the rectiers 5 After connection of battery, verify right polarity

by measuring the voltage drop across the battery breakers (normally not more than 5V DC).

6 Check oat charge, U1, and boost charge, U2.

It is to be adjusted according to the battery manufacturers requirements.

7 Check temperature compensation. It is to be

adjusted according to the battery manufacture requirements.

Check temperature read from the controller compared to the ambient temperature.

8 Check symmetry measurement and set number

of battery strings according to actual number of supervised battery strings in the system.

9 Check alarm transmission by running an alarm

test.

Checked

()

Result

L1-N:……….V AC

L2-N:...............V AC

L3-N:...............V AC

U1:…….V DC

U2:.........V DC

Comp.:…….V/10°C

Read o:………°C

Number: ….

Alarm limit:……

Document No. M00035-MAN rev. 3a

Table 5-2 Commissioning Record

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Chapter 6 Maintenance & Troubleshooting

6.1 Maintenance

Power system maintenance includes maintaining all parts of the system.

Annual maintenance should involve checking all connections on the terminals and circuit

breakers. Output voltage should be veried to be within the acceptable limits at least once a year. Test results should be recorded and led to see any deviations.

The power system requires periodic inspections and routine cleaning. It is very important to keep all areas and components of the system free from dust or other unwanted objects to ensure free air circulation and safe operation of the system.

CAUTION To undertake any further maintenance, strictly follow all manufacturer’s recommendations provided in the equipment manual.

6.2 Troubleshooting

This troubleshooting chapter helps to determine the cause of the problem and suggests

possible repair solutions. If the rst step of the recommendation does not solve the problem

continue to the next one.

NOTE If the malfunctioning of the system persists, please contact UNIPOWER technical support.

NOTE For a description of Alarms and Messages generated by the system controller see the Alarms/Messages section of the appropriate controller manual:

ACC Extended: http://www.unipowerco.com/pdf/acc-man.pdf PCC: http://www.unipowerco.com/pdf/pcc-man.pdf

By default, alarms are set to be indicated with a red light (higher priority) and messages with a yellow light (lower priority).

Fault Possible Cause Suggestion/Solution

Low System Voltage

High System Voltage

Module failure.

Loss of AC power.

Load exceeds module capacity.

Module failure.

System voltage exceeds the set limit.

Replace faulty module.

Verify AC input connection.

Add module to system.

Replace the faulty module.

Check the High Voltage Alarm limit setting.

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Fault Possible Cause Suggestion/Solution

Mains Error

AC supply OFF on one rectier in the system with one plugged in rectier.

Verify that the AC input breaker is ON.

AC Low Voltage

AC High Voltage

Module Failure

Urgent Module Failure

High Load

AC supply OFF on at least two

Verify AC input connection.

rectiers in the system with minimum two plugged in rectiers.

AC voltage drops below the set limit. Verify the Low AC voltage limit

setting.

Verify AC Input connection.

Verify AC Input voltage.

AC voltage rises above the set limit. Verify the High AC voltage limit.

Verify the AC Input voltage.

Faulty module.

AC OFF on a single rectier (if more than one rectier is installed).

Rectier current sharing fault.

Check if module sends alarm ag.

Verify the AC voltage to the failed module.

Re-insert the faulty module, wait for 30 seconds

Low DC output voltage, overvoltage shutdown, module fan failure, module

Replace the faulty module.

is overheated.

More than one rectier is reporting

See Module failure alarm.

Module failure.

Faulty module .

Compare the load current with

installed rectier capacity.

Rectier load current exceeds the set

High load limit [%].

Add a rectier or reduce load.

Overvoltage Shutdown

Load/Battery Disconnection

Document No. M00035-MAN rev. 3a

Verify the High load limit setting.

Replace the faulty module.

Faulty module Re-insert the module, wait for 5

minutes.

Replace the faulty module.

System voltage drops below the set

Check the battery condition.

limit.

Check the AC mains connection.

System shutdown.

Check the input breaker.

Check the rectier modules.

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Fault Possible Cause Suggestion/Solution

Communication Failure

Module failure.

Check the non-communicating address

Modules not installed in the correct position.

If the rectier address does not

communicate re-install the module

Broken or disconnected

and wait for 5 minutes.

communication wire.

Verify that the communication cable is properly connected and it is not damaged. Replace if necessary.

If the board address does not communicate, check if it is installed in the system. If it is, replace the board.

If there is a non-communicating module or unit, remove the noncommunicating address from the controller (Accept removed parts). Do so only if you are sure you do not use them any more.

Distribution Fuse Failure

Battery Fuse Failure

Tripped load breaker / blown load fuse.

Tripped load breaker / blown load fuse

Verify, if the controller is operating properly. If not, replace the controller.

Verify there is no short circuit in load cabling.

Reset the breaker, if it trips again, there is a problem with the load or a breaker itself.

Replace the breaker / fuse if necessary.

Verify there is no short circuit in load or battery cabling.

Verify the breaker / fuse is correctly rated.

Reset the breaker, if it trips again, there is a problem with the load or battery or a breaker itself.

Replace the breaker / fuse if necessary.

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Fault Possible Cause Suggestion/Solution

Symmetry Fault

Battery at end of life.

Verify the battery condition.

Low Battery Temperature

high Battery Temperature

Temp. Probe Failure

Alarms Blocked (only with LCD display)

Wrong symmetry cable connection.

Wrongly set Symmetry limit value.

Battery temperature drops below the set Low battery temperature limit.

Battery temperature exceeded the set limit.

The temperature probe is not properly connected to the system.

Faulty temperature probe.

Temperature probe wire is interrupted.

Temperature dierence between the

controller temperature and the probe temperature is greater than 60°C.

Alarm is manually activated by the serviceman on the site (used during system servicing, no other alarm is displayed)

Verify the symmetry cable connection.

Verify the Symmetry limit value.

Check the heating of the system.

Check the ambient temperature (it should not be lower than recommended battery temperature).

Check the cooling or ventilation.

Verify the battery condition.

Check the Battery Current Limit.

Verify the temperature probe connection.

Verify the internal / external temperature via controller front panel.

Replace the faulty probe with a new one.

Identify the root cause of the hot environment at the batteries and/or controller.

Needs to be manually turned OFF to allow the alarms to be displayed

If none of the above solves the problem please contact customer support.

To phone us please visit http://www.unipowerco.com/contact/ and select Customer “Support/

Repairs” and then “Customer Service” where you will nd the correct phone number for

your region.

Alternatively, email: sales@unipowerco.com

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Chapter 7 Replacing Modules

7.1 Controller Replacement

A faulty Controller can be easily replaced with a new one:

1. Loosen the front screw in the top left corner of the controller front panel using a at screwdriver, see Figure 7-1.

Figure 7-1 Unlocking the Controller

2. Pull the controller out of the shelf as shown in Figure 7-2.

Figure 7-2 Removing the Controller

3. Reverse the process to insert the new controller into the empty slot and fasten the screw.

CAUTION After controller start-up, verify if the appropriate conguration le is uploaded

to the controller. If necessary refer to the PowCom™ User Guide.

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7.2 Rectier Replacement

NOTE Rectiers can be hot-swapped.

7.2.1 XR04.48 / XR08.48 Replacement

To replace an XR04.48 or XR08.48 rectier, follow the steps below:

1. Loosen the screw on the rectier front panel using a screwdriver, Figure 7-3 (1).

2. Push the release spring to the right and at the same time pull the handle to remove the

rectier from the slot, Figure 7-3 (2).

3. Replace the module and fasten the screw.

Release spring

Handle

Figure 7-3 Replacing an XR04.48 or XR08.48 Rectier

7.2.2 XPGe12.48 Replacement

1. Insert a at screwdriver into the rectangular opening next to the left handle to unlock it, Figure 7-4 (1).

2. Once unlocked, pull both handles down and remove the rectier from the slot, Figure 7-4 (2).

3. Replace rectier. Make sure that the rectier handle is in OPEN position (forms 35-40°

angle with rectier body) before XPGe12.48 is fully inserted in the slot.

4. Push both handles upwards until the left handle locks the rectier into the correct position.

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POWERING TECHNOLOGY

1 2

Figure 7-3 Replacing an XPGe12.48 Rectier

CAUTION After rectier rebooting, check that the green LED is lit.

7.3 Breaker Replacement

WARNING Make sure the system is switched OFF.

To replace a faulty circuit breaker, follow the steps below:

1. Remove the top cover by loosening 4 screws on each side of the system and one screw at the rear, see Figure 7-5.

Document No. M00035-MAN rev. 3a

Figure 7-5 Top Cover Removal

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POWERING TECHNOLOGY

2. Pull the Faston connector from the circuit breaker, see detail in Figure 7-6 (1).

3. Press the top and bottom of the breaker, Figure 7-6 (2) to disengage it from its place and pull it out, Figure 7-7.

Figure 7-6 Breaker Removal - A

Figure 7-7 Breaker Removal - B

4. Snap in a new breaker of the same type.

5. Plug the Faston connector to the breaker.

6. Re-attach the top cover.

This document is believed to be correct at time of publication and UNIPOWER LLC accepts no responsibility for

consequences from printing errors or inaccuracies. Specications are subject to change without notice.

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USB 2.0 /

Appendix A - Block Diagram

XR08.48/ XR04.48

AC/DC Converter

XR08.48/ XR04.48

AC/DC Converter

4/9

RS 232

Ethernet

Jumper J1 and J2 on PCB must be removed, if the system is configured for 2x single phase input, see system Long Description

Note:

XPGe12.48/

ACC/PCC

System

Controller

Batt+

Batt-

F4+

F4-

F3+

F3-

F2+

F2-

F1+

F1-

+ V sys.

- V sys.

Digital Out2

Digital Out1

Digital In2

Digital In1

Alarm4 NO

Alarm4 NC

Alarm4 C

Alarm3 NO

Alarm3 NC

Alarm3 C

Alarm2 NO

Alarm2 NC

Alarm2 C

Alarm1 NO

Alarm1 NC

Alarm1 C

Ambient

Temperature

Battery

Temperature

Multipurpose 12

Multipurpose 11

Multipurpose 10

Multipurpose 9

Multipurpose 8

Multipurpose 7

Multipurpose 6

Multipurpose 5

Multipurpose 4

Multipurpose 3

Multipurpose 2

Multipurpose 1

X11

AC Input

BB In

BB Out

LB1 In LB2 In

LB3 In

LB4 In

LB1 Out

LB2 Out

LB3 Out

LB4 Out

RS485 Com.

X10

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Appendix B - CSA Certicate Extract

ELECTRICAL RATING

Input, AC Maximum Output, DC

Input Type V A (max) Hz V (dc) A

Single Phase (High Power) 100 - 240 16-11 50 - 60 46 - 57 52*

Two Phase (High Power) 100 - 240 8-5.5

50 - 60 46 - 57 52*

(Per phase)

Single Phase (Low Power) 100 - 240 9-4 50 - 60 46 - 57 15

Two Phase (Low Power) 100 - 240 4.5-2

50 - 60 46 - 57 15

(Per phase)

*Maximum output current is derated to: 25 A from 100-180 Vac and 23 A from 90-100 Vac at 47°C, 55°C ambient 21 A from 90 to 264 Vac at 75°C ambient 45 A from 180 Vac to 264 Vac at 55°C ambient

CONDITIONS OF ACCEPTABILITY

1. The shelves are to be installed only by trained service personnel, according to manufacturer installation instructions.

2. Evaluated as Class I (earthed equipment). Reliable earth connection shall be provided in the end use installation.

3. Evaluated for use in a Pollution Degree 2 environment, up to 3048 m altitude.

4. Temperature tests shall be considered for specic installation conditions in the end system.

5. Suitable re enclosure shall be provided in the end system.

6. All secondary output circuits for all models are SELV.

7. The shelves shall be properly bonded to the main protective earthing termination in the end product.

8. The input connectors for all models are suitable for eld connection.

9. These products are intended to be installed within equipment that is for use in a RESTRICTED ACCESS LOCATION (RAL) and the end-product instructions shall so state.

10. Consideration shall be given to the Output Terminals, that they do not exceed 85°C at the maximum operating ambient temperature.

11. These products are provided with component power supplies which are double-poled/neutral fused and marked per 2.7.6, which is visible after installation of power supplies. However, additional marking may be necessary based on installation of these products and should be considered during the end-product evaluation.

12. Consideration should also be given to re-conducting Temperature Tests if the equipment is intended for use in an ambient other than 47, 55 and 75°C .

13. Load breakers maximum load must not exceed the below limits:

14. 25 to 30 A circuit breaker rating- Maximum load per breaker must not exceed 18 A at 47 and 55°C ambient and not exceed 7.5 A at 75°C ambient 1 to 20 A circuit breaker rating- Maximum load per breaker must not exceed 80% of breaker current rating at 47 and 55°C ambient and not exceed 30% of breaker current rating at 75°C ambient.

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Appendix C - Revision History

Revision Page(s)

Altered

3a cover,

footer, 2

Description Approval/Date

Change of document number to reect new system, this placed

on front cover and in footer of all other pages. Update copyright date and contact numbers on front cover. Update feedback & support email address. Add appendix C - Revision History (this page).

04/26/2017

Document No. M00035-MAN rev. 3a

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Unipower Aspiro 1U, XPGe12.48, XR08.48, XR04.48 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Objectives

1.2 Audience

1.3 Document Key

1.4 Feedback & Support

1.6 Disclaimer

2.1 Overview

Figure 2-1 Power System Overview

2.3 System Parameters

2.4 System Components

2.4.1 System Controller

2.4.2 DC Distribution

Figure 2-2 XPGe12.48 and XR04.48/XR08.48

3.1 Safety Warnings and Guidelines

3.1.1 System Markings

3.1.2 Safety Recommendations

3.1.3 Installation Warning

3.1.4 Restricted Access Area Warnings

3.1.5 Electrical and Fire Enclosure

3.1.6 System Enclosure

3.1.7 Operating Temperature Warnings

3.1.8 Electrical Safety Warnings

3.1.9 Grounding

3.1.10 Batteries

3.1.10.1 Lead Acid Batteries

3.1.11 In Case of an Accident

3.2 Caution

3.2.1 Storage and Transportation

3.2.2 Disposal

3.2.3 Handling Electrostatic Sensitive Devices

3.2.4 Traceability

3.2.5 Breakers

3.2.5.1 Circuit Breaker Limitations

4.1 Introduction

4.2 Unpacking

4.3 Tools

4.4 Rack Mounting

Figure 4-1 Dimensional Drawing (Front and Top View)

Figure 4-2 System Mounting (19” mount)

4.5 Rear Connections

Figure 4-3 Rear Connections

4.5.1 DC Earth Connection (FRAME GROUND)

Figure 4-4 DC Earth Connections

4.5.2 Mains Connection

Figure 4-5 Mains Connection (viewed from rear)

Figure 4-6 Mains Connection Detail

4.5.3 Alarm and Signal Connections

Figure 4-7 Signal Pin Designations

Figure 4-8 Signal Connection Detail

4.5.4 DC Load Connections

Figure 4-9 Load and Battery Connections (Rear View)

4.5.5 Battery Connections

Figure 4-10 Signal Connection Detail

4.5.6 Symmetry Connection

Figure 4-11 2-block Symmetry Measurement (for illustration only)

Figure 4-12 4-Block Symmetry Measurement (for illustration only)

4.5.7 Temperature Sensor Connection

Figure 4-13 Temperature Sensor Connection

5.1 Commissioning Overview

5.2 Tools and Test Equipment

5.2.1 Tools List

5.2.2 Test Equipment

5.3 Preparation

5.4 Commissioning procedure

5.5 Test of output voltage

5.5.1 Float charge (U1)

5.5.2 Adjustment of Float Charge, U1

5.5.3 Boost charging (U2) (if applicable)

5.6 Battery supervision

5.7 Battery test

5.8 Commissioning record

6.1 Maintenance

6.2 Troubleshooting

7.1 Controller Replacement

Figure 7-1 Unlocking the Controller

Figure 7-2 Removing the Controller

7.2.1 XR04.48 / XR08.48 Replacement