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: [phone] • Fax: [phone] • [e-mail]

EUROPE • Parkland Business Centre, Chartwell Road, Lancing BN15 8UE, ENGLAND • Tel: [phone] • [e-mail]

© 2015 UNIPOWER LLC

All Rights Reserved

Copyright © 1999-2015 UNIPOWER LLC
All Rights Reserved
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.

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 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.

September 2015

Manual No. aspiro1u_ms22-1

Page 2

aspiro1u_ms22-man-0915.indd

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 Congurations ...............................................................................................................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 Rectier 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

Manual No. aspiro1u_ms22-1

Page 3

aspiro1u_ms22-man-0915.indd

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 Rectier 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

Manual No. aspiro1u_ms22-1

......................................................................................................42

Page 4

aspiro1u_ms22-man-0915.indd

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 Rectier ...........................................................................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

Manual No. aspiro1u_ms22-1

Page 5

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 6

aspiro1u_ms22-man-0915.indd

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/Pacic [e-mail]

Europe, Middle East and Africa [e-mail]

The Americas and Caribbean [e-mail]

1.5 Disclaimer

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

modication of the instructions provided in this manual.

Manual No. aspiro1u_ms22-1

Page 7

aspiro1u_ms22-man-0915.indd

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 or PCC

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

1
2

4

Manual No. aspiro1u_ms22-1

3

Figure 2-1 Power System Overview

Page 8

aspiro1u_ms22-man-0915.indd

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

Manual No. aspiro1u_ms22-1

Page 9

2

, spring type connector

2

, screw type connector

2

, screw type connector

2

, screw type connector

aspiro1u_ms22-man-0915.indd

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

Manual No. aspiro1u_ms22-1

Page 10

aspiro1u_ms22-man-0915.indd

RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48

E󰀩ciency 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

Manual No. aspiro1u_ms22-1

Page 11

aspiro1u_ms22-man-0915.indd

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.

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 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

Manual No. aspiro1u_ms22-1

Figure 2-2 Distribution Breaker Options

Page 12

aspiro1u_ms22-man-0915.indd

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.

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

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.

Manual No. aspiro1u_ms22-1

Page 13

aspiro1u_ms22-man-0915.indd

2.5 Operation

The Aspiro system is capable of delivering up to 2400W/48V steady state power . The system

is based on hot swappable rectier modules which work in parallel with automatic load

sharing.

The power shelf is normally congured with N+1 redundancy (1200W max.), with N as the
number of rectier modules necessary for feeding the load and charging the battery and 1
as the redundant rectier module. In normal operation the rectier modules are feeding the

load.
The system performance is supervised and controlled from the system controller. From this

unit, system settings such as output DC voltage and alarm thresholds are set. Any system
malfunction will be indicated by front panel LED indicators, text in the LCD and operation
of dry contacts. However, the controller is not a single point of failure. In the event of
malfunction in the controller, basic tasks like feeding the load will be maintained by the

rectier modules directly at preset default values.

The alarm and threshold setting of the Aspiro system can be set locally by use of the controller
push buttons and menu guided operation, or remotely using either the PowCom™ program
or the Web Interface.

Manual No. aspiro1u_ms22-1

Page 14

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 15

aspiro1u_ms22-man-0915.indd

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

T o 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.

Manual No. aspiro1u_ms22-1

Page 16

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 17

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 18

aspiro1u_ms22-man-0915.indd

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.

3.2.6 Hot Surfaces

CAUTION Areas of the Power System may become hot. Take precautions and handle
with care to avoid harm.

Manual No. aspiro1u_ms22-1

Page 19

aspiro1u_ms22-man-0915.indd

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:

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

• Anti-static hand strap.

• Insulated socket wrench .

• Insulated screwdriver set, at.

• Insulated Screwdriver set, torx.

• 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.

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

Manual No. aspiro1u_ms22-1

Page 20

aspiro1u_ms22-man-0915.indd

There needs to be sucient clearance at the front for rectier installation, and at the rear for

19.00 (482.6)

1.72

connections. When using side mains and DC connectors, sucient space should be allowed

for access in this case.

18.31 (465.1)

1.63

(41.3)

0.98
(25)

9.11 (231.5)

10.78 (273.7)

1.25

(43.70)

(31.75)

20.3 (515)

20.97 (532.5)

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

The Aspiro system can be easily mounted to a rack using the supplied 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.

Manual No. aspiro1u_ms22-1

Figure 4-2 System Mounting (19” mount)

Page 21

aspiro1u_ms22-man-0915.indd

4.5 Rear Connections

CONNECTIONS

BATTERY

AC

CONNECTIONS

SYMMETRY

CONNECTIONS

All cable connections for the Aspiro systems are available at the rear of the system. Load and
battery connections are performed at the rear of the breaker drawer, see Figure 4-3.

CAUTION Recommended wire sizes for mm² and AWG in the following are not given
as exact conversions, but as recommended sizes in standard values for each system. W ires
should be rated for 90°C and minimum 300V rating.

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.

LOAD

CONNECTIONS

SIGNAL

CONNECTIONS

EARTH

ALARM & TEMP.

CONNECTIONS

Figure 4-3 Rear Connections

4.5.1 DC Earth Connection

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

to ensure its safe and ecient operation.

Earth Connection of the rack can be made by using the M5 screw located on the rear as
shown in Figure 4-4. Earth connection is essential before connecting the mains to the power
system. Use a suitable cable lug for connection (M5) and a UL listed cable.

To connect:

Manual No. aspiro1u_ms22-1

1. Loosen the screw (M5).

2. Attach suitably sized cable lug.

3. Tighten the screw with torque 3.5Nm.
Recommended cable size is 6mm2 / 10AWG.

Figure 4-4 DC Earth Connections

Page 22

aspiro1u_ms22-man-0915.indd

4.5.2 Mains Connection

1-phase 2 x 1-phase

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

• 2 x 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.

E N L

Figure 4-5 Mains Connection (viewed from rear)

Shelf Type

(See product label)

Single-phase

AC Input

2 x Single-phase

AC Input

Table 4-1 Recommended Mains Circuit Protection

Number

of

Rectiers

2

2

E N2 L2 E N1 L1

Imax at

100 VAC

18.6 A

at 100VAC

9.3 A

at 100VAC

Recommended

Mains CB

D63A

2 x D63A

Manual No. aspiro1u_ms22-1

Page 23

aspiro1u_ms22-man-0915.indd

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 4mm

2

/ 12AWG.
Maximum torque required for tightening
the screw is 0.5Nm.

Figure 4-6 Mains Connection Detail

4.5.3 Alarm and Signal Connections

Conguration-specic Alarm Outputs, Symmetry Measurement Inputs and optional signals
are found on the right side and center as seen from the rear, see gure 4-8 for details. The
Symmetry inputs can also be recongured as external inputs. The conguration of alarms
and symmetry connections may vary depending on controller conguration.

NOTE Each alarm contact represents a dierent alarm condition or conditions. These is

dened in the controller’s alarm matrix setup.

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 16AWG.
Maximum torque required for tightening
the screw is 0.25Nm.

Manual No. aspiro1u_ms22-1

Figure 4-7 Signal Connection Detail

Page 24

aspiro1u_ms22-man-0915.indd

X16 X9 X15

a

a

b c

3

6

1

2

7 8 9

4

5

3

1

4 1

2

3

6

4

2

5

X8

3

1

2

X2

3

1

1

2

2

3

1

2

3

1

2

X10X6X4X3

3

1

2

LVD Reconnect C

LVD Disconnect C

LVD Disconnect NC

LVD Disconnect NO

PLD C

PLD NO

LVD Reconnect NC

LVD Reconnect NO

Symmetry 1

Symmetry 2

-36V

-24V

-12V

PLD NC

-48V

0V

Load Breaker

Current Shunt -

Battery Breaker

Current Shunt +

-48V

-36V

-24V

-12V
0V

GND 2

Vout +

Output Margin

(-)36V
(-)24V
(-)12V

(-)36V
(-)24V
(-)12V

GND 1

0V

Power Fail

Power Fail GND

1 2 3X74 5 6

Sense

+5V

C

NC

NO

Alarm 4 Alarm 3

System Vout +

System Vout +

Alarm Condition Shown

C
NC
NO

Releasing the alarm connector plugs

C

NC

NO

C

NC

NO

NC

Alarm 2 Alarm 1

Figure 4-8 Signal Pin Designations

NOTE With XR04.48 rectiers mounted, it is recommended to pull the mains cable

through the supplied ferrite to guarantee EN55022 Class B EMC standard compliance.

4.5.3.1 Cable Relief Kit

NO

C

The Aspiro power system is delivered with a kit for mounting a mains cable relief near the
mains connector. The kit may be mounted according to customer needs as shown in Figure
4-9.

Manual No. aspiro1u_ms22-1

Figure 4-9 Cable Relief Kit

Page 25

aspiro1u_ms22-man-0915.indd

4.5.4 DC Load Connections

+ F5 + F4 + F3 + F2 + F1

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

Figure 4-9 Load Connections (Rear View)

For DC load connections use the instructions given in Figure 4-6.
Maximum cable size is 4.0mm2 / 12AWG. Maximum torque required for tightening the

screw is 0.6Nm.

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

Load

Breaker Size

4A 5A 7.5A 10A 15A

[A]

Wire Size

2

[mm

/AWG]

1/18 1/18 1/18 1/18 2.5/14

Table 4-2 Cable Sizes

4.5.4.1 Circuit Breaker Limitations

The following breaker limitations apply. Ambient temperature below means the temperature

of the inow air to the system.

• 50°C Ambient - 40A max. total, 25A max. each breaker

• 65°C Ambient - 25A max. total, 12A max. each breaker

Manual No. aspiro1u_ms22-1

Page 26

aspiro1u_ms22-man-0915.indd

At 50°C ambient temperature all circuit breakers should be loaded to a maximum of 80%
rating. In addition, the following limitations apply:

• 15A breakers require one free space between breakers.

• Maximum battery charging is 50A.
At 65°C ambient temperature all circuit breakers should be loaded to a maximum of 70%

rating. In addition, the following limitations apply:

• When using circuit breakers rated 15A the maximum load per circuit breaker is 60% of
the rating. When using circuit breakers rated 15A one free space is required between
circuit breakers. Maximum combined input current is 28A.

• Maximum battery charging 50A.

At 75°C ambient temperature all circuit breakers should be loaded to a maximum of 50%
rating. In addition, the following limitations apply:

• When using circuit breakers rated 4A to 10A maximum load per circuit breaker is 50% of
the rating. When using circuit breakers rated 15A, the maximum load per circuit breaker
is 40% of the rating. When using circuit breakers rated 15A, one free space is required
between circuit breakers. Maximum combined input current is 18A.

4.5.5 Battery Connections

W ARNING 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.

WARNING The battery cables should be connected to the shelf 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 4-3, and are marker - and +. It is recommended to use 45 degree angled cable
lugs. The xing screws are size M6, and the cable lug can be maximum 15mm wide.

Recommended torque is 8Nm.

Manual No. aspiro1u_ms22-1

Page 27

aspiro1u_ms22-man-0915.indd

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 4-10.

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 4-11.

Figure 4-10 2-block Symmetry Measurement (for illustration only)

Figure 4-11 4-Block Symmetry Measurement (for illustration only)

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.

Manual No. aspiro1u_ms22-1

Page 28

aspiro1u_ms22-man-0915.indd

4.5.7 Temperature Sensor Connection

Temp. Sensor

T emperature 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 4-12.

NOTE Temperature sensor is normally pre connected to the system, see Figure 4-8.

Manual No. aspiro1u_ms22-1

Figure 4-12 Temperature Sensor Connection

Page 29

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 30

aspiro1u_ms22-man-0915.indd

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).

Manual No. aspiro1u_ms22-1

Page 31

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 32

aspiro1u_ms22-man-0915.indd

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:

T emperature 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 T est = 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™.

Manual No. aspiro1u_ms22-1

Page 33

aspiro1u_ms22-man-0915.indd

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:……

Manual No. aspiro1u_ms22-1

Table 5-2 Commissioning Record

Page 34

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 35

aspiro1u_ms22-man-0915.indd

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 V oltage

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

Manual No. aspiro1u_ms22-1

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.

Page 36

aspiro1u_ms22-man-0915.indd

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.

Manual No. aspiro1u_ms22-1

Page 37

aspiro1u_ms22-man-0915.indd

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.
T o 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:

Region Email Address

Asia/Pacic [e-mail]

Europe, Middle East and Africa [e-mail]

The Americas and Caribbean [e-mail]

Manual No. aspiro1u_ms22-1

Page 38

aspiro1u_ms22-man-0915.indd

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 and then pull the controller out of the shelf, see Figure 7-1.

1

2

Figure 7-1 Unlocking and removing the Controller

2. 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.

Manual No. aspiro1u_ms22-1

Page 39

aspiro1u_ms22-man-0915.indd

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 same procedure as for the controller.

7.2.2 XPGe12.48 Replacement

1. Insert a at screwdriver into the rectangular opening next to the left handle to unlock it,
Figure 7-2 (1).

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

1 2

Figure 7-2 Replacing an XPGe12.48 Rectier

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

Manual No. aspiro1u_ms22-1

Page 40

aspiro1u_ms22-man-0915.indd

7.3 Breaker Replacement

b

2

3

WARNING Make sure the system is switched OFF.

To replace a faulty circuit breaker, follow the steps below, see gure 7-3:

1. Remove the breaker front cover.

2. First apply a spanner to the breaker fastening nut at the front (2a) then loosen the breaker
(2b). Unplug the breaker and remove it (2c).

3. Insert the replacement breaker in the vacant slot (3a), apply the fastening nut (3b) and
fasten it (3c).

c

a

Figure 7-5 Breaker Replacement

a

b

c

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.

Manual No. aspiro1u_ms22-1

Page 41

aspiro1u_ms22-man-0915.indd

Rectifiers

Configuration with 5 x load breakers shown

Appendix A - Block Diagram

L
N
PE

20

+ Vout

- Vout

X1

XR08.48
XR08.48
XPGe12.48

ACC/ PCC
control unit

Distribution

Backplane

L PE

N

X21 -Xn1* X11

X4

N

L PE

96

J3

10

J12 Display

BM0714

Distribution Board

F1

F2
F3

F4
F5

20

+

96

X12

RS485

RS485

X5

X6

-

4

4

X14

Output
enable

Output
enable

X10

1 2

X8

GreenTBlue

Signalization

and

control

-

X13

22

Temperature

sensor

Red

GND

+

1 2 3

LVD discon
LVD recon

Shunt +
Shunt -

X12
X11

System voltage

and Alarm relays

X9

16

9

J2

J1

8

Ethernet

RS 232 / USB

2
4
6
8

10

0V Load

F1

F2

- Load

F3

F4

F5-1

X10

F5-1
F5-1
F5-1
F5-1

GND

1 2 3

Analog

Measurement

X7

GND

Multipurpose 5

4 5 6

GND

Multipurpose 4

F5

Multipurpose 3

Manual No. aspiro1u_ms22-1

Page 42

aspiro1u_ms22-man-0915.indd