Unipower Aspiro 1UMS22 Instruction Manual
Power Supply System
Aspiro 1U - MS22
Instruction Manual
www.unipowerco.com
Document Number: ASPIRO1U_MS22-1
aspiro1u_ms22-man-0915.indd
NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: +1 954-346-2442 • Fax: +1 954-340-7901 • sales-northamerica@unipowerco.com
EUROPE • Parkland Business Centre, Chartwell Road, Lancing BN15 8UE, ENGLAND • Tel: +44(0)1903 768200 • sales-europe@unipowerco.com
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Copyright © 1999-2015 UNIPOWER LLC
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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 specically 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
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aliated with UNIPOWER LLC or our products. They do not sponsor or endorse our products.
LIMIT ATIONS AND AUTHORIZA TIONS FOR USE AND PERMITTED APPLICA TIONS
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 ocer 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.
September 2015
Manual No. aspiro1u_ms22-1
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Contents
Chapter 1 About This Manual ......................................................................................................6
1.1 Objectives ..................................................................................................................................6
1.2 Audience ....................................................................................................................................6
1.3 Document Key ...........................................................................................................................6
1.4 Feedback & Support ..................................................................................................................7
Chapter 2 Aspiro System Description ..........................................................................................8
2.1 Overview ....................................................................................................................................8
2.2 System Congurations ...............................................................................................................8
2.3 System Parameters .....................................................................................................................9
2.4 System Components.................................................................................................................12
2.4.1 System Controller ...........................................................................................................12
2.4.2 DC Distribution ...............................................................................................................12
2.4.4 Rectier Module .............................................................................................................12
2.5 Operation ..................................................................................................................................14
Chapter 3 System Safety..............................................................................................................15
3.1 Safety Warnings and Guidelines ..............................................................................................15
3.1.1 System Markings ............................................................................................................15
3.1.2 Safety Recommendations ................................................................................................15
3.1.3 Installation W arning ........................................................................................................16
3.1.4 Restricted Access Area W arnings....................................................................................16
3.1.5 Electrical and Fire Enclosure ..........................................................................................16
3.1.6 System Enclosure ............................................................................................................16
3.1.7 Operating Temperature Warnings ...................................................................................16
3.1.8 Electrical Safety Warnings ..............................................................................................16
3.1.9 Grounding .......................................................................................................................17
3.1.10 Batteries ........................................................................................................................18
3.1.10.1 Lead Acid Batteries .........................................................................................18
3.1.11 In Case of an Accident ..................................................................................................18
3.2 Caution .....................................................................................................................................19
3.2.1 Storage and Transportation .............................................................................................19
3.2.2 Disposal...........................................................................................................................19
3.2.3 Handling Electrostatic Sensitive Devices .......................................................................19
3.2.4 Traceability .....................................................................................................................19
3.2.5 Breakers ..........................................................................................................................19
3.2.6 Hot Surfaces ....................................................................................................................19
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Chapter 4 Installation Guide ......................................................................................................20
4.1 Introduction ..............................................................................................................................20
4.2 Unpacking ................................................................................................................................20
4.3 Tools 20
4.4 Rack Mounting .........................................................................................................................20
4.5 Rear Connections .....................................................................................................................22
4.5.1 DC Earth Connection ......................................................................................................22
4.5.2 Mains Connection ...........................................................................................................23
4.5.3 Alarm and Signal Connections ........................................................................................24
4.5.3.1 Cable Relief Kit ...........................................................................................................25
4.5.4 DC Load Connections .....................................................................................................26
4.5.4.1 Circuit Breaker Limitations .........................................................................................26
4.5.5 Battery Connections .......................................................................................................27
4.5.6 Symmetry Connection ....................................................................................................28
4.5.7 Temperature Sensor Connection .....................................................................................29
Chapter 5 Commissioning ...........................................................................................................30
5.1 Commissioning Overview .......................................................................................................30
5.2 Tools and Test Equipment ........................................................................................................30
5.2.1 T ools List .........................................................................................................................30
5.2.2 T est Equipment ...............................................................................................................30
5.3 Preparation ...............................................................................................................................30
5.4 Commissioning procedure .......................................................................................................31
5.5 Test of output voltage ...............................................................................................................32
5.5.1 Float charge (U1) ............................................................................................................32
5.5.2 Adjustment of Float Charge, U1 .....................................................................................32
5.5.3 Boost charging (U2) (if applicable) ................................................................................32
5.6 Battery supervision ..................................................................................................................33
5.7 Battery test ...............................................................................................................................33
5.8 Commissioning record .............................................................................................................34
Chapter 6 Maintenance & Troubleshooting ..............................................................................35
6.1 Maintenance .............................................................................................................................35
6.2 Troubleshooting .......................................................................................................................35
Chapter 7 Replacing Modules .....................................................................................................39
7.1 Controller Replacement ...........................................................................................................39
7.2 Rectier Replacement ..............................................................................................................40
7.2.1 XR04.48 / XR08.48 Replacement ..................................................................................40
7.2.2 XPGe12.48 Replacement ................................................................................................40
7.3 Breaker Replacement ...............................................................................................................41
Appendix A - Block Diagram
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FIGURES
Figure 2-1 Power System Overview .............................................................................................8
Figure 2-2 Distribution Breaker Options ....................................................................................12
Figure 2-2 XPGe12.48 and XR04.48/XR08.48 ..........................................................................13
Figure 4-1 Dimensional Drawing (Front and Top View) ............................................................21
Figure 4-2 System Mounting (19” mount) .................................................................................21
Figure 4-3 Rear Connections ......................................................................................................22
Figure 4-4 DC Earth Connections ..............................................................................................22
Figure 4-5 Mains Connection (viewed from rear) ......................................................................23
Figure 4-6 Mains Connection Detail ..........................................................................................24
Figure 4-7 Signal Connection Detail ..........................................................................................24
Figure 4-8 Signal Pin Designations ............................................................................................25
Figure 4-9 Cable Relief Kit ........................................................................................................25
Figure 4-9 Load Connections (Rear View) .................................................................................26
Figure 4-10 2-block Symmetry Measurement (for illustration only) ...........................................28
Figure 4-11 4-Block Symmetry Measurement (for illustration only) ..........................................28
Figure 4-12 Temperature Sensor Connection ...............................................................................29
Figure 7-1 Unlocking and removing the Controller ...................................................................39
Figure 7-2 Replacing an XPGe12.48 Rectier ...........................................................................40
Figure 7-5 Breaker Replacement ................................................................................................41
TABLES
Table 4-1 Recommended Mains Circuit Protection ..................................................................23
Table 4-2 Cable Sizes ................................................................................................................26
Table 5-1 Float/Boost Charge Voltages .....................................................................................32
Table 5-2 Commissioning Record .............................................................................................34
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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 denes 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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T able 1-1 Abbreviations
Abbreviation Description
PPS P1 Power Supply System
PMP P1 Modular Power
CMP Convection-cooled Modular Power
FMP Fan-cooled Modular Power
PCS P1 Control and Supervision
PCU P1 Control Unit
GMC Galero Modular Controller
PPR P1 Power Rack
PBDU P1 Battery Distribution Unit
PBC P1 Battery Cabinet
PDU P1 Distribution Unit
PPRD P1 Power Rack with DC Distribution
PPC P1 Power Supply Cabinet
PBF P1 Battery Fuse Unit
PCB Printed Circuit Board
LVD Low voltage disconnection
PLD Partial load disconnection
MCB Miniature circuit breaker
MCCB Moulded case circuit breaker
1.4 Feedback & Support
For technical support or feedback, please visit http://www.unipowerco.com/contact/ and
select Customer “Support/Repairs” and then “Customer Service”.
Alternatively, email:
Region Email Address
Asia/Pacic Sales-Asia@unipowerco.com
Europe, Middle East and Africa Sales-NorthAmerica@unipowerco.com
The Americas and Caribbean Sales-NorthAmerica@unipowerco.com
1.5 Disclaimer
UNIPOWER is not responsible for system problems that are the result of installation or
modication of the instructions provided in this manual.
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Chapter 2 Aspiro System Description
2.1 Overview
Aspiro DC power systems oer 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 ecient, dense, and reliable plug-in rectier modules
XR04.48, XR08.48 or XPGe12.48, with output power available at either 400W, 800W or
1200W per rectier, based upon a soft-switching approach. Features include wide input
operating range, wide operating temperature, full self-protection and three LEDs for
immediate rectier 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 Congurations
Aspiro 1U system consists of:
1. System Controller ACC Extended or PCC
2. 4 x Load and 1 x Battery breakers including LVD
3. XR04.48 / XR08.48 / XPGe12.48 Rectiers (Maximum 2)
4. Rear Connections
1
2
4
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3
Figure 2-1 Power System Overview
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2.3 System Parameters
OUTPUT
Power (max) 2400W @ >180VAC, 800W @ <180VAC
Output Current (max) 24A (XPGe12.48), 18.6A (XR08.48), 11A (XR04.48)
Float Voltage 53.5VDC
Voltage Range 46-57VDC
INPUT
Voltage 85-300VAC (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 (with appropriate option selected)
Load Breakers
Ratings
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
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)
4 or 5 (depending on option selected)
4A, 5A, 7½A, 10A or 15A
Yellow LED - Message(s)
Red LED - Alarm(s)
CONNECTIONS
Battery connections Stripped cable, max.16mm
AC connections Stripped cable with ferule, max. 2.5mm
Load breaker connections Stripped cable with ferule, max. 4mm
Alarm connections Stripped cable with ferule, max. 1.5mm
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2
, spring type connector
2
, screw type connector
2
, screw type connector
2
, screw type connector
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MECHANICAL
Dimensions (WxHxD) 482.6mm x 44.45mm x 280mm
Weight of the system
6.5 kg
(fully equipped)
Mounting Options 19”/ ETSI / Mid-mount
Cable Entry Rear Access
Enclosure IP20
STANDARD COMPLIANCE / ENVIRONMENTAL
Emmissions
Conducted
Radiated
Harmonics
Voltage uctuation and
CISPR 22/EN 55022/EN 61204, GR1089, R-3-6 Class B
CISPR 22/EN 55022/EN 61204 Class B
IEC/EN 61000-3-2
IEC/EN 61000-3-3
icker
Voltage Sag
SEMI F47-0200 (230VAC)
Immunity
ESD
Electromagnetic Field
Fast Transients
Surges
IEC/EN 61000-4-2, level 4 (contact/air) 8/15kV - Performance criterion B
IEC/EN 61000-4-3, level 3 10V/m - Performance criterion A
IEC/EN 61000-4-4, level 3 (in/out) 2/1kV - Performance criterion B
Surges - IEC/EN 61000-4-5, level 3 (L/L, L/E) 2/4kV - Performance criterion B
Telecordia GR-1089-cove, level 2 (L/L,L/E) 6/6kV - Performance criterion D
Voltage dips and
interruptions
IEC/EN 61000-4-11
Dip 30%, 100ms - Performance criterion A
Dip 30%, 200ms - Performance criterion B
Dip 60%, 20ms - Performance criterion A
Dip 60%, 100ms - Performance criterion B
Dip >95%, 20ms - Performance criterion A
Dip >95%,100ms - Performance criterion B
Conducted RF
IEC/EN 61000-4-6 10VAC, AM 80%, 1kHz - Performance criterion A
Safety EN 60950-1
Environment Storage - ETS 300 019-2-1
Transport - ETS 300 019-2-2
Operation - ETS 300 019-2-3
Operating Temperature -40°C to +75°C
Storage Temperature -40°C to +85°C
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RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48
Eciency 95% typical @ I
nom 90% typical @ I
out
nom 88% typical @ I
out
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
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2.4 System Components
The Aspiro system is delivered with all components mounted according to the ordered
conguration. The main components are described below and in later chapters of the manual.
2.4.1 System Controller
The Aspiro 1U 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
The Aspiro 1U system is available with two distribution options as below:
• 5 x Load Breaker B-Frame type drawer
• 4 x Load and 1 x Battery breaker drawer, includes LVD
2.4.4 Rectier Module
The Fan-Cooled XPGe12.48 (1200W), XR08.48 (800W) and XR04.48 (400W) rectiers
are modular power supplies designed for parallel operation and hot-plug installation in
the Aspiro Power Systems.
Each rectier 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 rectiers. This guarantees
Manual No. aspiro1u_ms22-1
Figure 2-2 Distribution Breaker Options
Page 12
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tightly controlled load sharing among rectiers, and provides status and identication
information to the controller.
The rectiers 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 rectier is automatically adjusted to the required
voltage by the controller.
Figure 2-2 XPGe12.48 and XR04.48/XR08.48
XPGe12.48 rectiers cannot be used in the same rack as XR04.48 / XR08.48 rectiers.
CAUTION XPGe12.48 rectiers cannot be used in the same system as XR04.48/
XR08.48 rectiers.
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