Unipower DPP1U-A1, DPP1U-A6, DPP1U-A1-B1-S, DPP1U-A6-B6-S, DPP1U-A1-B1 Operating Manual
...
POWERING TECHNOLOGY
OPERATING MANUAL
DPP1U SERIES
DC POWER DISTRIBUTION PANELS
Manual No. DPP1U-5
dpp1u-man-Rev5-0317.indd
www.unipowerco.com
© 2017 UNIPOWER LLC
All Rights Reserved
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
OPERATING MANUAL
DPP1U SERIES
Contents
1.0 INTRODUCTION ...............................................................................................................4
2.0 FEATURES ..........................................................................................................................4
3.0 PRODUCT LINE .................................................................................................................5
4.0 SAFETY & INDUSTRY STANDARDS .............................................................................5
5.0 WARRANTY (summary) ....................................................................................................6
6.0 DESCRIPTION OF OPERATION ......................................................................................6
7.0 SPECIFICATIONS ..............................................................................................................7
8.0 FRONT PANEL DESCRIPTION ........................................................................................8
9.0 BACK PANEL DESCRIPTION ..........................................................................................8
10.0 UNP ACKING AND INSPECTION ...................................................................................10
11.0 INSTALLATION ...............................................................................................................11
12.0 INSTALLING CIRCUIT BREAKERS .............................................................................12
13.0 SETUP AND TESTING ....................................................................................................13
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POWERING TECHNOLOGY
OPERATING MANUAL
DPP1U SERIES
FIGURES
Figure 1. DPP1U DC Power Distribution Panel ..........................................................................4
Figure 2. Block Diagram ..............................................................................................................6
Figure 3. Front Panel View ..........................................................................................................8
Figure 4. Back Panel View ...........................................................................................................8
Figure 5. Input Bus Bar Detail .....................................................................................................8
Figure 6. Output Barrier Strip Detail ...........................................................................................9
Figure 7. Alarm Contact Detail ....................................................................................................9
Figure 8. Series Connection of Multiple Panels .........................................................................11
Figure 9. Cover plate removal ....................................................................................................12
Figure 10. Breaker or blank panel removal ..................................................................................12
Manual No. dpp1u-5
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POWERING TECHNOLOGY
OPERATING MANUAL
DPP1U SERIES
OPERATING MANUAL
DPP1U SERIES DC POWER DISTRIBUTION PANELS
1.0 INTRODUCTION
UNIPOWER’s DPP1U Series of circuit breaker panels provide distribution and overload protection
for 1 to 16 circuits with circuit breakers that can be eld installed/exchanged without the need for
any additional tools. The panels are only one mounting position (1.75 inches) high.
The panels provide up to 16 breakers single bus 150A or 8A+8B 150A+150A distribution and alarm
capabilities. The A and B sections of the dual-bus panel are fully isolated, can be separately congured
for 12 or 24/48 volts and are polarity neutral. Breaker capacities range from 1 to 30 amperes.
Breaker alarm is indicated by a dual color LED (green/red) and Form C relay contacts for each bus
.
Figure 1. DPP1U DC Power Distribution Panel
2.0 FEATURES
2.1 The following is a summary of the important features of the DPP1U Series.
48/24V and 12V or Dual Voltage
POLARITY NEUTRAL
150A bus bar inputs
Single or Dual Feed
NO tools required to change breakers
Tapered entry for easy insertion
NO or NC alarm contacts
Alarm LEDs
Power Fail form-C alarm
19" & 23" universal mounting brackets
Rear panel safety cover standard
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POWERING TECHNOLOGY
3.0 PRODUCT LINE
3.1 StandardCongurations
The following table lists the 8 available standard congurations of the DPP1U series.
DPP1U SERIES
OPERATING MANUAL
MODEL
NUMBER
DPP1U-A1 48/24
DPP1U-A6 12
DPP1U-A1-B1-S 48/24
DPP1U-A6-B6-S 12
DPP1U-A1-B1 48/24 - 48/24
DPP1U-A6-B6 12 - 12
DPP1U-A1-B6 48/24 - 12
DPP1U-A6-B1 12 - 48/24
VOLTS
EACH FEED
INPUT
FEEDS
1 8 150 150
1 16 150 150
2 8 + 8 150 300
MAX. #
BREAKERS
AMPS
EACH
FEED
TOTAL
AMPS
3.2 Available Breakers
AMPS PART NUMBER AMPS PART NUMBER AMPS PART NUMBER
1 348-1436-0000 10 348-1436-0030 25 348-1436-0060
2.5 348-1436-0010 15 348-1436-0040 30 348-1436-0070
5 348-1436-0020 20 348-1436-0050 BLANK 348-1418-0000
Breakers need to be ordered individually and are shipped with each panel as separate items
for eld installation.
4.0 SAFETY & INDUSTRY STANDARDS
4.1 DPP1U Series power distribution panels meet the following safety requirements:
STANDARD
UL60950-1, 2nd Edition
CSA22.2 No. 60950-1, 2nd Edition
EN60950-1, 2nd Edition
4.2 DPP1U Series power distribution panels are CE marked to indicate conformance to the
European Union’s Low Voltage Directive.
4.3
These Distribution Panels operate at voltages that could potentially be hazardous.
Furthermore, inadvertent short circuiting of the system battery and/or rectier by mis-
connection or other error could be harmful. This product should be handled, tested and
installed only by qualied technical persons who are trained in the use of power systems
and are well aware of the hazards involved.
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POWERING TECHNOLOGY
BATT.
BATT.
INPUT
INPUT
RET.
CIRCUITS
CIRCUITS
A SIDE B SIDE
4.4 When operating this Distribution Panels the chassis ground terminal must be connected to
the system frame ground or other proper safety ground for the protection of personnel.
All connections to the Distribution Panels should be carefully checked for errors before
4.5
applying power to them.
4.6
The internal voltages may be at hazardous potentials. The top cover should not be removed.
There are no user-serviceable components in these units. Removing the top cover will void
the warranty.
5.0 WARRANTY (summary)
DPP1U Series power distribution panels are warranted for two (2) years from date of shipment
against defects in material and workmanship. This warranty does not extend to products which have
been opened, altered or repaired by persons other than persons authorized by the manufacturer or to
products which become defective due to acts of God, negligence or the failure of customer to fully
follow instructions with respect to installation, application or maintenance.
DPP1U SERIES
OPERATING MANUAL
For a complete text of UNIPOWER’s warranty conditions please request a copy from your local
Sales Oce.
6.0 DESCRIPTION OF OPERATION
6.1 Power Distribution Circuits. A simplied schematic diagram of the distribution panels
is shown in Figure 2. The battery input to each load connects to a high-current copper bus
bar from which the individual fuses or circuit breakers distribute power to the loads. The
return input connects to a similar bus bar to which the individual loads terminate. The A
and B loads are totally independent and isolated with the exception of models incorporating
the ‘S’ option.
RET.
HI-CURRENT BUS BAR HI-CURRENT BUS BAR
1 2 3... N
LOADS LOADS
HI-CURRENT BUS BAR HI-CURRENT BUS BAR
A SIDE
ALARM
-S OPTION
CIRCUIT
BREAKERS
-S OPTION
1 2 3... N
B SIDE
ALARM
Figure 2. Block Diagram
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POWERING TECHNOLOGY
6.2 Alarm Circuits. The alarm circuits detect a tripped circuit breaker and, in this event, turn
on the red part of the LEDs. The alarm circuits also each drive Form C relay contacts. If
one or more circuits open or if there is an input power failure, the relays are de-energized
and the contacts are used to control external audible or visual alarms. The A and B alarm
circuits are also independent and isolated from each other.
7.0 SPECIFICATIONS
The following specications are typical at 25°C unless otherwise noted.
LED & RELAY STATE MEANINGS
LED State Relay State Meaning
Green Energized (N.O. is closed) OK
Red
OFF No Input Power
De-energized
(N.O. is open)
Breaker Trip
or
Breaker OFF
DPP1U SERIES
OPERATING MANUAL
INPUT/OUTPUT
Input/Output Ratings......................... 150A Max. @ 40°C, each side A & B
125A Max. @ 50°C, each side A & B
50A Max. @ 70°C, each side A & B
See manual for details on CB deratings
Conguration .................................150A Single Bus with 1 to 16 Breakers
300 A Dual Bus 1 to 8 Breakers
Each Bus
Breaker Capacity
1
Voltage
24/48V Version .....................................................................21-60VDC
12V Version .......................................................................10.5-15VDC
Polarity ............................................Neutral, Positive or Negative Ground
ALARMS
Alarm Indicator ................................................... Dual Color LED Per Bus
LED Status Indication ........................................................Green = Normal
Red = CB Trip Alarm
O = No Power
Alarm Relays ..............................................Form C Contacts for each Bus
SAFETY ......................UL60950-1 2nd Ed., CSA22.2 No. 60950-1 2nd Ed.,
EN60950-1 2
1
......................................................................1A to 30A
nd
Ed.
For thermal reasons, it is recommended when operating the panel continuously at the ambient
temperatures dened above, the circuit breaker current shall not exceed the limits as dened below.
40°C Ambient:
150A Max., the CB current should be limited to 18.75A Max.
125A Max., the CB current should be limited to 22.5A Max.
50°C Ambient:
125A Max., the CB current should be limited to 15.6A Max.
100A Max., the CB current should be limited to 21A Max.
70°C Ambient:
50A Max., the CB current should be limited to 15A
ENVIRONMENTAL
Operating T emp. Range .....................................................-10°C to +70°C
Storage T emp. Range ........................................................-40°C to + 85°C
Humidity........................................................0% to 95%, Non-Condensing
PHYSICAL SPECIFICATIONS
Case Material .....................................................................................Steel
Finish ............................................................................Powder Coat Black
Case Dimensions, Inches (mm) .......................1.74 H x 17.12 W x 8.94 D
(44.2 x 434.9 x 227.1)
Weight ...................................................................... 10.30 lbs. ( 4.67 kg.)
Rack Mounting..................................................................... 19 or 23 Inch
CONNECTIONS
Input Connections......................................Crimp Type Lug or ¼ - 20 Stud
Output Connections .................................Barrier Terminal Strips, No. 6-32
Chassis Ground Connection.................................................No. 8-32 Stud
Alarm Relay Connections ................. .Spring Clamp Terminals,16-26A WG
Notes:
1. See ordering guide to specify.
Manual No. dpp1u-5
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POWERING TECHNOLOGY
17.12 (434.9)
1.74
(44.2)
FRONT VIEW
Case depth: 8.94 (227.1)
A Side Breakers B Side Breakers
150A MAX PER BUS
150A MAX PER BUS
A B
ALARM
1 18
8
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
17.12 (434.9)
1.74
(44.2)
Alarm LEDs
REAR VIEW
FRONT VIEW
Case depth: 8.94 (227.1)
A Side Breakers B Side Breakers
2.28
(57.8)
Clear Perspex
Safety Cover
0.34”
0.375”
0.65”
0.32”
DPP1U SERIES
OPERATING MANUAL
8.0 FRONT PANEL DESCRIPTION
The front panel of the DPP1U, shown in Figure 3 below, consists of the A and B sides and a center
section. The A and B sides can each accommodate up to 8 eld installable/replaceable hydraulic
magnetic circuit breakers rated from 1A to 30A. The center section has two green/red LEDs, one
for the A side (left) and the other for the B side (right). At the bottom of this center section is a slot
for a wallet and designator card. This card permits the recording of each output circuit by number.
ON
I
O
OFF
150A MAX PER BUS
ON
ON
ON
ON
ON
ON
I
I
I
I
O
O
OFF
O
OFF
OFF
I
O
O
OFF
OFF
ON
I
I
O
O
OFF
OFF
1 18
ALARM
A B
Alarm LEDs
ON
I
O
OFF
Figure 3. Front Panel View
9.0 BACK PANEL DESCRIPTION
9.1 Back View. Figure 4 shows the back of the DPU1U distribution panel. Inputs are at the left
and right ends of the back panel. Side B outputs are at two rows of barrier terminal strips
on the left side, and side A outputs are the same on the right side. At the center of the back
panel are two spring clamp terminal blocks for the Form C relay contact outputs.
Below these is a chassis ground terminal.
ALM B
ALM A
BAT
RTN
B Input
¼-20 Studs
1 2 3 4 5 6 7 8
B Outputs
6-32 Terminal Strip
BAT
NO-C-NC NO-C-NC
RTN RTN
Alarm
Contacts
Figure 4. Back Panel View
BAT
Ground
8-32 Stud
6-32 Terminal Strip
150A MAX PER BUS
ON
ON
ON
I
O
O
OFF
OFF
1 2 3 4 5 6 7 8
ON
I
I
O
OFF
OFF
A Outputs
ON
ON
I
I
O
O
OFF
ON
I
I
O
O
OFF
OFF
8
BAT
RTN
A Input
¼-20 Studs
Manual No. dpp1u-5
9.2 Input Connections. See Figure 5. The DC power inputs to the distribution panels are made
by means of crimp type lugs or direct connection to ¼-20 studs to two copper bus bars on
side A and side B. The upper bus bar is the battery connection (whether + or -) and the
lower bus bar is the return (whether + or -).
0.625”
Figure 5. Input Bus Bar Detail
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POWERING TECHNOLOGY
0.375”
DPP1U SERIES
OPERATING MANUAL
9.3 Crimp Type Lugs. A list of compatible crimp type lugs is shown in the following table
for AWG wire sizes from no. 1 to 8 and one- or two- hole lugs. These lugs can be ordered
directly from the manufacturer, Panduit Corp., using the model numbers shown in the table.
A standard kit of four two-hole crimp type lugs for no. 6 AWG copper wire is available from
UNIPOWER. Order kit no. 775-1434-0000.
WIRE
AWG
8
6
4
2
1
.25DIA.
HOLES
1
2
1
2
1
2
1
2
1
2
PANDUIT CORP.
PART NUMBER
LCA8-14-L
LCD8-14A-L
LCA6-14-L
LCD6-14A-L
LCA4-14-L
LCD4-14A-L
LCA2-14-Q
LCD2-14A-Q
LCA1-14-E
LCD1-14A-E
UNIPOWER
PART NUMBER
625-1665-0010
625-1665-0110
625-1665-0020
625-1665-0120
625-1665-0030
625-1665-0130
625-1665-0040
625-1665-0140
625-1665-0050
625-1665-0150
9.4 Output Connections. Output connections for A and B loads are shown in Figure 4. There
are 8 sets of barrier terminal strip connections for each side, A and B. The connections
are numbered to correspond with the numbers of the front panel breakers. The upper strip
connections are from the battery through the breakers; the lower strip connections are the
returns. Side B is on the left and side A on the right, as shown.
Each terminal is a no. 6-32 screw and is rated at 30 amperes. Wire sizes from no. 12 AWG
to no. 22 AWG may be used for connections. Figure 6 below shows detailed spacing of the
terminals.
Manual No. dpp1u-5
0.65”
0.32”
Figure 6. Output Barrier Strip Detail
9.5 Form C Relay Contact Outputs. The center of the back panel has connections to the
Form C relay contact outputs for connection to external audible or visual alarm circuits.
See Figure 7 below.
Figure 7. Alarm Contact Detail
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POWERING TECHNOLOGY
OPERATING MANUAL
DPP1U SERIES
Connection is made via two Phoenix Contact spring clamp terminal blocks. ALM-B is
for the Form C relay contact of side B and ALM-A is for the Form C relay contact of side
A. The terminals, viewed from left to right, are the normally open (NO) common (C) and
normally closed (NC) contacts, respectively. See gure 8 below.
“Normally Closed” and “Normally Open” are dened with the distribution panel powered
and providing power to all outputs, i.e. no circuit breakers tripped.
The ratings of the relay contacts are 0.6A at 125VAC or 2A at 30VDC. The spring clamp
terminals accept wire sizes nos. 16 to 26 AWG.
When the input power is connected to a side (A or B), the Form C relay of that side is
energized. If there is either loss of input power, one or more circuit breakers trip or the relay
is de-energized, the normally open contacts close and the normally closed contacts open.
9.6 Chassis Ground Connection. Just below the Form C relay contact terminals is the chassis
ground terminal. This terminal is a no. 8-32 stud with a nut.
NOTE THAT IT IS ESSENTIAL THAT THIS TERMINAL IS CONNECTED TO THE
SYSTEM FRAME GROUND TO ENSURE SAFE OPERATION.
10.0 UNPACKING AND INSPECTION
10.1 This DPP1U Series power distribution panel was carefully tested, inspected and packaged
for shipment from our factory . The unit and circuit breakers are shipped separately. Upon
receipt of the unit it should be carefully unpacked and inspected for any damage in shipment.
10.2 If there is evidence of damage, do not attempt to test the unit. The freight carrier should
be notied immediately and a claim for the cost of the rectier system should be led with
the carrier for direct reimbursement. Be sure to include the model and serial number of the
damaged unit in all correspondence with the freight carrier. Also save the shipping carton
and packing material as evidence of damage for the freight carrier’s inspection.
10.3 UNIPOWER will cooperate fully in case of any shipping damage investigation.
10.4 Always save the packing materials for later use in shipping the unit. Never ship the rectier
system without proper packing.
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POWERING TECHNOLOGY
11.0 INSTALLATION
11.1 Mounting. This distribution panel can be mounted in either 19- or 23-inch racks by using
the supplied reversible brackets. Mount it from the front of the rack using the correct osets
to align with existing rack-mounted equipment.
The bracket osets are every quarter inch from front to back.
11.2 Connections. Input connections should be made with one- or two-terminal crimp type lugs
using copper wire size from no. 1 to 8 AWG, depending on current and wire loop distance.
See Sections 9.2 and 9.3. Output connections are made to the barrier terminal strips. See
Section 9.4 and Figure 6.
NOTE: Single feed models DPP1U-A1-B1-S and DPP1U-A6-B6-S have both left and
right side input bus bars tted. It is only necessary to connect the input feed to one side for
correct operation.
The unused side is directly connected to the live input feed and can be used for supplying
additional panels. See gure 8 below.
DPP1U SERIES
OPERATING MANUAL
CAUTION: The total load must not exceed 150A on any one pair of bus bars in the chain.
ALM B ALM A
BAT
150A MAX. FEED
RETURN
BAT
RTN
BAT
RTN
BAT
RTN
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
NO-C-NC NO-C-NC
RTN RTN
ALM B ALM A
BAT
NO-C-NC NO-C-NC
RTN RTN
ALM B ALM A
BAT
NO-C-NC NO-C-NC
RTN RTN
BAT
BAT
BAT
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BAT
RTN
BAT
RTN
BAT
RTN
Figure 8. Series Connection of Multiple Panels
The Form C relay contact output connections are made to the spring clamp terminal blocks.
See Section 9.5. The chassis ground connection is made to the no. 8-32 stud. See Section
9.6. This safety ground connection should be made before operating the panel.
11.3 Checking Connections. Carefully check the polarity of input connections to the distribution
panel and output connections to the load before operating the panel. Reverse connections
will not harm the distribution panel which is POLARITY NEUTRAL but may cause serious
harm to the load. Check to make sure that the chassis safety ground connection is made.
Make sure that all connections are clean and secure to minimize contact resistance.
11.4 Rear Safety Cover. Once all of the above have been completed, t the clear plastic safety
cover to the back of the unit using the supplied mounting studs and screws. Instruction for
tting the mounting studs the panel are included in the accessory kit.
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POWERING TECHNOLOGY
150A MAX PER BUS
A B
ALARM
1
8
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
ON
I
O
OFF
17.12 (434.9)
1.74
(44.2)
FRONT VIEW
DPP1U SERIES
OPERATING MANUAL
12.0 INSTALLING CIRCUIT BREAKERS
The DPP1U Series employs pluggable circuit breakers that can be easily installed, removed or
replaced without the need for an tools. The cover-plate that is xed over the breakers is designed to
be used to extract existing circuit breakers or blanking panels. This operation is carried out without
the need to dismount the unit from it’s installation.
Installation, removal or replacement of a circuit breaker and connection or disconnection of a load
circuit should be carried out only by only by qualied technical persons who are trained in the use
of power systems and are well aware of the hazards involved.
Although it may be necessary on some occasions to carry out this operation while power remains
applied to the panel, it is always preferable to switch o the power if possible before proceeding.
12.1 Removing the cover plate. To remove the cover plate under the two knurled retaining
screws and pull forward. See gure 9 below.
retaining screws
150A MAX PER BUS
ON
ON
ON
ON
ON
ON
ON
OFF
ON
I
I
O
O
OFF
extraction tab
8
I
I
I
I
I
OFF
I
O
O
OFF
O
O
O
OFF
OFF
OFF
OFF
O
1
Figure 9. Cover plate removal
12.2 Removing a breaker or blanking panel. To remove a breaker or blanking panel place
the tab at the end of the cover plate under the top edge of the breaker or blanking panel and
lever out carefully. See gure 10 below.
INSERT EXTRACTION TAB
HERE TO LEVER OUT
ON
ON
I
I
O
O
OFF
OFF
Figure 10. Breaker or blank panel removal
12.3 Installing a breaker or blank panel. Carefully push the breaker or blank panel rmly into
the socket and make sure that it is fully seated.
Repeat the above procedure from 12.2 to 12.3 for all positions and then replace the cover
plate.
12.4 Connecting or disconnecting load circuits. In cases where a breaker has been installed
follow the instructions in section 9.4 to connect the new output wiring. Ensure that the
breaker is in the OFF position until all connections have been made and thoroughly checked.
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POWERING TECHNOLOGY
Note that if power remains applied to the panel during breaker installation the alarm
LED will show red and the alarm relay will be activated until the new cables have been
connected and the breaker set to the ON position.
13.0 SETUP AND TESTING
13.1 It is not necessary to have the distribution panel mounted in a rack for initial testing. This
can be done on a bench. It is also not necessary to have loads connected to the panel for
this testing.
13.2 With the input power source o, connect the input wires to the A side of the distribution
panel. Connect ground to the chassis ground terminal. Set all circuit breakers to on.
13.3 Turn on the input power source. The A side LED should be green. If it is red, one of the
circuit breaker is tripped. If the LED is o, there is no input power to the unit. Check the
output voltage at each set of output terminals with a digital voltmeter.
DPP1U SERIES
OPERATING MANUAL
13.4 With the A side LED green, use an ohmmeter to check the Form C relay contact outputs.
On J4 measure the resistance between pins 1 and 2. This should read “open”. Measure the
resistance between pins 2 and 3. This should read “short”.
13.5 On the A side trip circuit breaker no. 1. The A side LED should turn red. On J4 measure the
resistance between pins 1 and 2. This should read “short”. Measure the resistance between
pins 2 and 3. This should read “open”. Reset the circuit breaker.
13.6 On the A side check each succeeding breaker by tripping it, and verify that the LED turns
red. It is not necessary to recheck the Form C relay contacts.
13.7 Repeat the same tests of Sections 13.2 through 13.6 on the B side of the distribution panel,
use J3 to check the Form-C relay operation.
13.8 The distribution panel may now be connected to its intended application.
13.9 If the distribution panel did not operate properly in the above tests, go back and double
check the connections and the polarity of the input source to make sure it is correct.
Please note that there are no user serviceable parts inside either the modules or the shelves
and that opening either will void the warranty.
If you are unable to resolve any problem call your nearest UNIPOWER sales oce for
support:
US +1 954 346 2442 UK +44 (0)1903 768200
This document is believed to be correct at time of publication and UNIPOWER LLC accepts no responsibility for
consequences from printing errors or inaccuracies. Specications are subject to change without notice.
Manual No. dpp1u-5
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