Unipower Guardian Access 3U, FMPe20.48G, FMPe30.48G, FMP25.48G Instruction Manual

POWERING TECHNOLOGY

Power Supply System

Guardian Access 3U

Instruction Manual

www.unipowerco.com

Document Number: MS0027-MAN rev. 4

guardian_access_3u_ms27-man-rev4-0817.indd

© 2017 UNIPOWER LLC

All Rights Reserved

UNIPOWER LLC • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • [e-mail]

North America: [phone] • Europe: [phone]

POWERING TECHNOLOGY

Copyright © 1999-2017 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.

Manual No. MS0027-MAN rev. 4

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Contents

Chapter 1 About This Manual ......................................................................................................6

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

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

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

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

1.5 Disclaimer ..................................................................................................................................7

Chapter 2 System Description ......................................................................................................8

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

2.2 System Parameters

2.3 System Components.................................................................................................................13

2.3.1 System Controller ...........................................................................................................13

2.3.2 DC Distribution Unit.......................................................................................................13

2.3.3 Rectier Module .............................................................................................................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 System Enclosure ............................................................................................................16

3.1.6 Operating Temperature Warnings ...................................................................................16

3.1.7 Electrical Safety Warnings ..............................................................................................17

3.1.8 Grounding .......................................................................................................................18

3.1.9 Batteries ..........................................................................................................................18

3.1.9.1 Lead Acid Batteries .............................................................................................18

3.1.10 In Case of an Accident ..................................................................................................19

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 ..........................................................................................................................20

3.2.6 Hot Surfaces ....................................................................................................................20

...................................................................................................................11

Chapter 4 Installation Guide ......................................................................................................21

4.1 Preparation ...............................................................................................................................21

4.1.1 Installation Overview ......................................................................................................21

4.1.2 Unpacking .......................................................................................................................21

4.1.3 T ools ................................................................................................................................22

4.1.4 Cable Size .......................................................................................................................23

4.2 Rack Mounting .........................................................................................................................24

Manual No. MS0027-MAN rev. 4

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4.3 Cable Entry ..............................................................................................................................26

4.3.1 Remove Top Cover .........................................................................................................26

4.3.2 Cable Entry Openings .....................................................................................................27

4.5 AC Input Connection ...............................................................................................................29

4.6 DC Load Connection ...............................................................................................................31

4.7 Battery Connection ..................................................................................................................32

4.8 Alarm and Signal Connections .................................................................................................32

4.9 Symmetry Connection .............................................................................................................35

4.10 Temperature Sensor Connection ............................................................................................36

4.11 Connecting an RS232 Communication Cable .......................................................................37

4.12 Rectier Installation

...............................................................................................................37

4.13 Reinstalling Top Cover ..........................................................................................................38

Chapter 5 Commissioning

5.1 Commissioning Overview

...........................................................................................................39

.......................................................................................................39

5.2 T ools and Test Equipment ........................................................................................................39

5.2.1 T ools List .........................................................................................................................39

5.2.2 T est Equipment ...............................................................................................................39

5.3 Preparation

5.4 Commissioning procedure

...............................................................................................................................39

.......................................................................................................40

5.5 Test of output voltage ...............................................................................................................41

5.5.1 Float charge (U1) ............................................................................................................41

5.5.2 Adjustment of Float Charge, U1 .....................................................................................41

5.5.3 Boost charging (U2) (if applicable) ................................................................................41

5.6 Battery supervision

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

5.7 Battery test ...............................................................................................................................42

5.8 Commissioning record .............................................................................................................43

Chapter 6 Maintenance & Troubleshooting ..............................................................................44

6.1 Maintenance

.............................................................................................................................44

6.1.1 Checking Terminal Connection ......................................................................................44

6.1.2 Other Requirements ........................................................................................................44

6.2 Troubleshooting .......................................................................................................................45

Chapter 7 Replacing Modules .....................................................................................................49

7.1 Controller Replacement

7.2 Rectier Replacement

...........................................................................................................49

..............................................................................................................49

7.3 Battery and Load Breakers Replacement .................................................................................50

7.4 Surge Protection Device Replacement .....................................................................................50

Appendix A - Drawings ................................................................................................................51

A.1 System Layout
A.2 Installation Details - Connections
A.3 Block Diagram
A.4 Detailed Dimensions

Manual No. MS0027-MAN rev. 4

.........................................................................................................................51

...........................................................................................52

........................................................................................................................53

...............................................................................................................54

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FIGURES

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

Figure 2-2 Principal of Operation .................................................................................................9

Figure 2-3 Power System With Extension Rear and Top Cover Kit ..........................................10

Figure 2-4 Power System with Rear and Top Cover Kit ............................................................10

Figure 2-5 Guardian Rectier .....................................................................................................14

Figure 4-1 System Mounting - Cabinet ......................................................................................24

Figure 4-2 System Mounting - Open frame / relay rack .............................................................25

Figure 4-3 Remove Top Cover ...................................................................................................26

Figure 4-4 Remove Top and AC Input Cover .............................................................................27

Figure 4-5 Cable Entry Options ..................................................................................................27

Figure 4-6 Grounding Connection ..............................................................................................28

Figure 4-7 Grounding Connection with Extended Rear Cover - Two Point ..............................28

Figure 4-8 Grounding Connection with Extended Rear Cover - Single Point ...........................29

Figure 4-9 AC Input Terminal Block (1-phase) ..........................................................................30

Figure 4-10 AC Input Terminal Block (3-phase) ..........................................................................30

Figure 4-11 DC Load Connection ................................................................................................31

Figure 4-12 Battery Connection ...................................................................................................32

Figure 4-13 PCC External Board ..................................................................................................33

Figure 4-14 ACC External Board .................................................................................................33

Figure 4-15 ACC Relay Board .....................................................................................................34

Figure 4-16 2-block Symmetry Measurement (for illustration only) ...........................................35

Figure 4-17 4-Block Symmetry Measurement (for illustration only) ..........................................35

Figure 4-18 Temperature Sensor Connection ...............................................................................36

Figure 4-19 RS232 Connection ....................................................................................................37

Figure 4-20 Rectier Installation ..................................................................................................38

Figure 7-1 Unlocking and Removing the Controller ..................................................................49

Figure 7-2 Replacing a Surge Protection Module ......................................................................50

TABLES

Table 4-1 Recommended Electrical Cable Size ........................................................................23

Table 5-1 Float/Boost Charge Voltages .....................................................................................41

Table 5-2 Commissioning Record .............................................................................................43

Table 6-1 Connection Torque Setting Check ............................................................................44

Manual No. MS0027-MAN rev. 4

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Chapter 1 About This Manual

1. About This Manual

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

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

cautions and noteworthy information.

1.1 Objectives

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

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

1.2 Audience

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

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

1.3 Document Key

This manual uses the following conventions:

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

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

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

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

Manual No. MS0027-MAN rev. 4

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T able 1-1 Abbreviations

Abbreviation Description

ACC Advance Controller Card
ACDU AC Distribution

DC Distribution Cabinet
EC Extension cabinet
FMD Fan-cooled Modular Power Converter
FMP Fan-cooled Modular Power Rectier
GDN Guardian system
Genset Diesel Generator
HCC Lite Hybrid Controller Card Lite
LVD Low voltage disconnection
MC Main Cabinet
MCCB Molded Case Circuit Breaker
MCB Miniature circuit breaker
P1 Power One
PBC P1 Battery Cabinet
PBDU P1 Battery Distribution Unit
PCC Prime Controller Card
PDU P1 Distribution Unit
PLD Partial load disconnection
SLI SLI Inverter

1.4 Feedback & Support

For technical support or feedback, please visit http://www.unipowerco.com/contact/.
Alternatively, email: [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. MS0027-MAN rev. 4

Page 7

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6

4

1

Chapter 2 System Description

2.1 Overview

This chapter contains an overview of the system and a short description of the units in the
system.

The Guardian Access 3U power system is designed to meet the requirements of modern

telecommunications equipment. This power solution provides rectication, system

management and power distribution. The power system is based the Guardian family of

on fan-cooled, hot-swappable rectier modules FMPe20.48G, FMP25.48 or FMPe30.48G;

each with an output of up to 2000W , 2500W or 2900W respectively. T wo additional modules

FMP20.48 and FMPe30.48C at 2000W and 2900W are also available in the Asia / Pacic

region.
The power system can be managed locally through messages and alarms displayed on the

LCD screen of system controller, or remotely using the PC-based PowCom™ software
package.

The power system contains 3 or 5 rectier positions and modules depending on your order,

one system controller, and distribution unit.
The Guardian Access 3U system consists of:

1. System Controller

2. Internal Connection Board

3. Rectier Module

4. Load and Battery Distribution

7

2

Figure 2-1 Power System Overview

5. Alarm Interface Board

6. AC Surge Protection Device (Option)

7. AC Input Terminal Block

5

3

NOTE If you order a power system with 3 rectier positions, the bottom two slots will be

unavailable and should be left blank.

Manual No. MS0027-MAN rev. 4

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POWERING TECHNOLOGY

The Guardian Access 3U is capable of delivering up to 14.7kW steady state power to the
combined load and batteries. The maximum power available to the load is 10.7kW. The

system is based on hot-swappable 48V rectier modules which are working in parallel with

automatic load sharing.

The power system is normally congured with N+1 redundancy, 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 used to feed the

load and simultaneously maintain the batteries in a fully charged state.

Once the mains input power is failed, the rectiers are shut down and the batteries feed

the load immediately. If the battery voltage drops below a preset level, the Low Voltage
Disconnection (L VD) circuit disconnects the batteries automatically to prevent over-discharge

of the battery to prolong battery life. When the mains input power is restored, the rectiers

will start up automatically to feed the load, close LVD circuit and recharge the batteries.
System performance is supervised and controlled by the controller, PCC or ACC Extended.

The DC output voltage, alarm thresholds, LVD circuit operation, temperature compensated
battery charging can be set by the controller . Any malfunction will be indicated by LED, text
in the display and operation of dry contacts.

However, the system controller is not a single point of failure. In the event of controller
malfunction, basic tasks like feeding the load and charging batteries will be maintained by

the rectier modules directly at preset default values.

The alarm and threshold setting of the power system can be set either through the buttons
and operation menu on the local controller, or remotely through the PowCom™ supervision
software.

Controller

DC Distribution

AC

Rectifier

Rectifier

Load Breakers

LVBD

Battery Breaker

Manual No. MS0027-MAN rev. 4

Battery

Figure 2-2 Principal of Operation

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POWERING TECHNOLOGY

DC & Alarm
Cable Entry

AC Cable Entry

DC & Alarm
Cable Entry

AC Cable Entry

To meet the requirements of dierent application, there are two kinds of Rear and Top Cover

Kit available:

• Rear and Top Cover Kit for cabinets

• Extension Rear and Top Cover Kit for open relay racks.

Figure 2-3 Power System With Extension Rear and Top Cover Kit

NOTE The cable entry on the rear of the shelf is factory supplied and opened. If you want
to route the cables from the bottom or side, remove the knockouts. For AC cable entry , you
have to install the supplied PG21.

Figure 2-4 Power System with Rear and Top Cover Kit

NOTE The Rear and Top Cover Kit and Extension Rear and Top Cover Kit are optional
components and just provided according to your order.

Manual No. MS0027-MAN rev. 4

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2.2 System Parameters

OUTPUT

Power (max) 10.7kW load + 4kW battery charge @ 230/400VAC nominal

9.4kW load + 4kW battery charge @ 120VAC nominal

Output Current (max) 200A load + 75A battery charge @ 230/400VAC nominal

175A load + 75A battery charge @ 120VAC nominal

Voltage 44-57.6VDC

INPUT

Voltage Range 100-120VAC, 1W+N+PE, 50/60Hz

200-240VAC, 2W+PE, 50/60Hz

208-240/360-416VAC, 3W+N+PE, 50/60Hz
Frequency 47-63Hz
Input Current 1-phase 82A @ 100-120VAC, 65A @ 200-240VAC

3-phase 25A per phase @ 230/400VAC
Power factor >0.98
Surge Protection Optional

DC DISTRIBUTION & BATTERY MANAGEMENT

Battery Breakers 1, 2 or 3 x 80A, 100A or 125A
Symmetry Inputs Up to 6
Programmable LVD / PLD 125A or 200A (voltage) / 125A or 200A (voltage/time)
Load Breakers 9 x 18mm / 13 x 13mm, depending on number of battery breakers.
Ratings

(see datasheet for details)

single pole - 4A, 6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, 63A

two pole - 80A, 100A; three pole - 125A, 150A

MONITORING AND CONTROL

Controller PCC or ACC Extended
Local Interface 4 x 20’ LCD, 4-key menu, USB (ACC only) and RS232
Remote Interface Ethernet / Modem using PowCom™ software
Visual Indication Green LED - System On

Yellow LED - Message(s)

Red LED - Alarm(s)
Analog Inputs 12 x voltage inputs (range 0-100VDC) - 6 max. for symmetry
Alarm Outputs 4 x potential free relays (C, NC, NO)
Digital Inputs 2 x, Logic 0: U<10VDC, Logic 1: U>12VDC (ACC only)
Digital Outputs 2 x, open collector type (ACC only)
Temperature measurement 2 x Temperature probe (Battery, Ambient)

CONNECTIONS

Battery connections M8 lugs, +Ve common from bus bar
AC connections Max. 7AWG/10mm

2

, screw type connector

Load breaker connections -Ve termination direct to breakers, +Ve common from busbar

11AWG/4mm²
Alarm connections Max. 14AWG/1.5mm², screw type connector

Manual No. MS0027-MAN rev. 4

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MECHANICAL

Dimensions (WxHxD) 19” (483mm) x 5.2” (133mm) x 16.1” (408mm) std cover | 19.1”

(485)mm ext. cover
Weight of the system

67lbs (30.5kg)
(fully equipped)

Mounting Options 19”/ Mid-mount
Cable Entry Rear Access (top/rear covers have to be removed to make

connections)

STANDARD COMPLIANCE / ENVIRONMENTAL

EMC and Immunity EN 300 386 ; EN61000-6-3 (Emission) ; EN61000-6-2 (Immunity)
Safety IEC60950-1:2005 2 Ed. +A1:2009
Environment

Storage : ETS300 019-2-1, Transport: ETS300 019-2-2, Operation

ETS300 019-2-3, Damp Heat: IEC60068-2-78
Operating Temperature -40°C to +65°C (derated above 55°C)
Storage Temperature -40°C to +85°C

RECTIFIER MODEL FMPe20.48G FMP25.48G FMPe30.48G

E󰀩ciency 96% 92.5% 95%
Input Current (max) <11.6A <16.8A <17.0A
Output Current

37.4A 46.7A 54.2A

(53.5V oat)

Output Power 1100W @ >180VAC

2000W @ 90-180VAC

Operating Temperature

55°C 55°C 55°C

1400W @ >180VAC

2500W @ 90-180VAC

1700W @ >180VAC

2900W @ 90-180VAC

(without derating)
Input Voltage

90-300VAC 85-300VAC

(Nominal 100-240VAC)
Output Voltage 44-57.6VDC
Load sharing < 5% of nominal current
Dimensions (HxWxD) 1.6 (41) x 4.2 (107) x 14 (355) ”(mm)
Weight 4.6lbs / 2.1kg
Cooling Fan-cooled, speed controlled
Protection Short circuit, automatic current/power limiting,

input/output overvoltage, thermal

Alarms Fan failure, Short circuit/arcing protection,

High temperature/output voltage Low output voltage,

Input voltage out of range Low fan speed (warning)

Internal communication failure

LED Indication Green:

AC normal operation
Yellow: Steady - Low fan speed, High temperature
Flashing - Communications failure
Red: Module alarm / shutdown

Audible noise <45dBA @ ≤25°C (50% load) | <60dBA (100% load)

Manual No. MS0027-MAN rev. 4

Page 12

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POWERING TECHNOLOGY

NOTE For details of FMP20.48 and FMP30.48C available only in APAC region please
see individual datasheets.

2.3 System Components

With the exception of the rectier modules the Guardian Access 3U system is delivered with
all components mounted according to the ordered conguration. The main components are

described below and in later chapters of this manual.

2.3.1 System Controller

The Guardian 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

2.3.2 DC Distribution Unit

The distribution unit includes congurable load breakers, battery breakers, a shunt for

battery current measurement and fuse alarms for load and battery breakers.
The distribution unit has no special operation other than switching the load and battery

breakers on and o. All trip states of breakers are supervised by measuring the voltage

drop across each breaker.
Breakers that are not connected to any load will not cause a breaker alarm even if they

are left open.

A battery fuse alarm may not be triggered instantly when a battery breaker is o. The

alarm is triggered only when the voltage drop between the system voltage and the battery
voltage is more than 1.5V. The interval that the voltage drop increases to 1.5V depends
on the battery status.

Due to a small leakage current (2.5-3mA) through the alarm circuit, the voltage measured
with a Digital Volt Meter (DVM) on an open breaker output will be nearly equal to the

rectier output voltage.

The distribution module has common “+Ve” with load breakers in “-Ve” leg. For more

information see schematic drawing in Appendix A - Drawings.

Manual No. MS0027-MAN rev. 4

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POWERING TECHNOLOGY

Cooling Fans

Status LEDs

2.3.2.1 Low Voltage Disconnect (LVD) and Dummy LVD

Generally , the system is equipped with low voltage battery disconnection, which prevents
the batteries from deep discharging, thus prolonging the battery life. A disconnection
requires a detected mains failure at the supervision unit.

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

If disconnection occurs, the batteries will be reconnected when mains supply returns.
A dummy LVD can also be installed into the power system if the Low Voltage

Disconnection function is not needed.

2.3.2.2 Partial Load Disconnection / Load Shedding (PLD)

Partial load disconnection can be congured to be voltage or time dependent, this is

selected when ordering the power system.
At a mains outage the controller will open the PLD contactor when the batteries have

discharged to a certain voltage or if the battery voltage has been under a certain voltage
for a predetermined time. The disconnection has to be set according to the present load
and battery manufacturer’s discharge tables or requirements.

2.3.3 Rectier Module

The fan-cooled rectier converts the AC input to -48VDC output for loads and batteries.

It is designed for parallel operation and plug-in installation in the power shelf and supplies
extremely stable DC power.

Each rectier incorporates an internal microprocessor that sends frequent updates to the
system controller and adjacent rectiers. This ensures accurately controlled load sharing
among rectiers and supplies status and identication information to the controller.

The rectier module features two LEDs for status indication, thermal protection with
power derating, and input over voltage disconnection with automatic reset. The rectier

module is hot-swappable and can be quickly removed and replaced without disrupting
the system or load.

Handles

Manual No. MS0027-MAN rev. 4

Figure 2-5 Guardian Rectier

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POWERING TECHNOLOGY

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 inside the system.
Safety Label - The safety label is located inside the system.

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. MS0027-MAN rev. 4

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POWERING TECHNOLOGY

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 should only be moved by qualied personnel and equipment.

• The Power System should be properly mounted to the building structure at the install
location to prevent bodily injury.

• Installation of the equipment in the rack should be properly installed so that hazardous
conditions are not present due to uneven loading.

• When installing the system in a rack, allow adequate room to prevent blocking of the
vent openings on the power equipment and to allow for optimal air circulation and to
reduce the chance of system overheating.

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.

NOTE This may be disregarded for systems delivered in a UNIPOWER Outdoor enclosure.

3.1.5 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.

3.1.6 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.

Manual No. MS0027-MAN rev. 4

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3.1.7 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.

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.

Manual No. MS0027-MAN rev. 4

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3.1.8 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.

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.

CAUTION A conductor is connected between the ground point and the 0 VDC bus bar
on the PBDU distribution. This conductor is connected to its own earth bar and not shared
with other safety conductors.

3.1.9 Batteries

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

3.1.9.1 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.

Manual No. MS0027-MAN rev. 4

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3.1.10 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.

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.

Manual No. MS0027-MAN rev. 4

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3.2.5 Breakers

Maximum 45°C operating ambient:

1. UP to 32A CB maximum load must not exceed 80% of it’s rating.

2. 40A CB maximum load shall not exceed 30A.

3. 50-63A CB maximum load shall not exceed 35A.
Maximum 55°C operating ambient:

1. Up to 20A CB maximum load must not exceed 80% of it’s rating

2. 25A to 63A CB maximum load must not exceed 60% of it’s rating.
Maximum 65°C operating ambient:

1. Up to 20A CB maximum load must not exceed 80% of it’s rating

2. 25A to 63A CB maximum load must not exceed 50% of it’s rating.

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 bodily harm.

Manual No. MS0027-MAN rev. 4

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Chapter 4 Installation Guide

4.1 Preparation

4.1.1 Installation Overview

The following is the recommended sequence for the installation procedures. The sequence

may change according to job or actual conguration.

• Unpack and check that all the equipment and materials have been delivered.

• Obtain the recommended tools.

• Check the connecting cable size.

• Mount the power system subrack to a cabinet or an open frame.

• Remove the top cover and knockouts for cable entry (if extension cover kit is ordered).

• Connect the earth grounding cable.

• Connect the AC input power.

• Connect the loads to the Distribution Unit as required.

• Connect the battery cables between power system and batteries.

• Connect the external alarm, symmetry cable and temperature sensor cable as required.

• Connect the RS232 communication cable (if RJ45-DB9 cable is ordered).

• Insert the rectiers into the rectier frame.

• Reinstall the top cover (If cover kit is ordered)

4.1.2 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.

Manual No. MS0027-MAN rev. 4

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4.1.3 Tools

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

• Anti-static hand strap.

• Socket wrench, insulated.

• Screwdriver set, at, insulated.

• Screwdriver set, torx, insulated.

• Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated.

• Torque spanner (for battery connection), insulated.

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

CAUTION Installation in USA / Canada must conform with the requirements in
NEC/CEC.

CAUTION Care must be taken when installing this system. The units can be damaged
and can cause damage if not handled with care. Pay particular attention to the order in
which units are installed.

Manual No. MS0027-MAN rev. 4

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4.1.4 Cable Size

Please use the recommended cable size given below for the system installation.

Port Current

Max.

AC Input -L1 32A 10mm² 7 AWG 105°C
AC Input -L2 32A 10mm² 7 AWG 105°C
AC Input -L3 16A 10mm² 7 AWG 105°C
AC Input -N 32A 10mm² 7 AWG 105°C
AC Input -PE - 10mm² 7 AWG 105°C
Battery MCB 80A 20mm² 4 AWG 105°C
Battery MCB 100A 25mm² 3 AWG 105°C
Battery MCB 125A 35mm² 2 AWG 105°C
DC Load -MCB 63A 16mm² 5 AWG 105°C
DC Load -MCB 50A 14mm² 6 AWG 105°C
DC Load -MCB 40A 10mm² 7AWG 105°C
DC Load -MCB 32A 8mm² 8 AWG 105°C
DC Load -MCB 25A 8mm² 8 AWG 105°C
DC Load -MCB 20A 6mm² 9 AWG 105°C
DC Load -MCB 16A 4mm² 10 AWG 105°C
DC Load -MCB 10A 2.5mm² 14 AWG 105°C
DC Load -MCB 6A 2.5mm² 14 AWG 105°C
DC Load -MCB 4A 1.5mm² 15 AWG 105°C

Cable Size

Min.(mm²)

Cable Size
Min.(AWG)

Temperature

Rating

Table 4-1 Recommended Electrical Cable Size

Circuit Breakers must not exceed the below loading based on maximum 55°C operating
ambient:

• For load breaker rated 5 to 32A, the maximum load must not exceed 80% of rating value.

• For load breaker rated up to 63A, the maximum load shall not exceed 40A if space is
provided between breakers. Maximum 30A is allowed if no space provided.

• For battery breaker rated up to 80A, the maximum load shall not exceed 80% of rating
value.

• For battery breaker rated 100 to 125A, the maximum load shall not exceed 75A.

Manual No. MS0027-MAN rev. 4

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4.2 Rack Mounting

There are two mounting brackets installed on the front left and right side of the power system
to enable you to securely fasten the sub-rack to a cabinet or an open frame.

NOTE For ease of mounting the power rack it is recommended to remove the rectiers.

NOTE When mounting the system to an open frame, the brackets should be moved to the

middle position.

To mount the subrack into a cabinet, follow the steps below:

1. Determine the installation position according to system measurement. Refer to the
Appendix A for details. Re-install the mounting bracket in another position if necessary.

Refer to the gure 4-1 below.

Two ways to install mounting
brackets in the front position

Figure 4-1 System Mounting - Cabinet

2. Place the system into the cabinet.

3. Fasten the system into the cabinet by using four M6 x 12mm screws and mounting
brackets on the front left and right side of the unit. Tighten the screws to 6 Nm.

Manual No. MS0027-MAN rev. 4

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To mount the system into an open frame, follow the steps below:

1. Determine the installation position according to system measurement. Refer to the
Appendix A for details.

2. Remove the mounting brackets on the front left and right side of the system.

3. Rex the mounting brackets to the middle left and right side of the system.

4. Place the system into the open frame.

5. Fasten the system to the open frame by using four M6 x 12mm screws and the mounting
brackets. Tighten the screws to 6 Nm.

Manual No. MS0027-MAN rev. 4

Figure 4-2 System Mounting - Open frame / relay rack

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Front Panel

4.3 Cable Entry

If the Rear and Top Cover Kit or Extended Rear and Top Cover Kit is installed on the power
system, the top cover should be removed for connecting AC, DC, alarm and temperature
sensor cables.

4.3.1 Remove Top Cover

To remove the top cover of Rear and Top Cover Kit, follow the steps below:

1. Remove the front panel of the Distribution Unit by loosing two screws.

2. Push the top cover backward and then lift to remove the it.

Top Cover

Figure 4-3 Remove Top Cover

To remove the top cover of Extended Rear and Top Cover Kit, follow the steps below:

1. Remove the front panel of the Distribution Unit.

2. Push the top cover backward and then lift to remove it for access to the DC and alarm
connection.

3. Remove the AC input cover of the Extension Rear and Top Cover Kit for access to the
AC connection.

Manual No. MS0027-MAN rev. 4

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DC cable entry from rear DC cable entry from bottomDC cable entry from rear

Top Cover

Front Panel

AC Input Cover

Figure 4-4 Remove Top and AC Input Cover

4.3.2 Cable Entry Openings

The Extended Rear and Top Cover is designed with two knockouts and one circular opening
for AC cable entry plus and three larger openings for DC and alarm cable entry.

When connecting and routing the AC cable from the right hand side or the bottom, rst
remove the knockout, then install the supplied PG21 to x the AC cable.

Figure 4-5 below depicts three types of AC and DC cable entry.

AC cable entry from side AC cable entry from bottomAC cable entry from rear

Manual No. MS0027-MAN rev. 4

Figure 4-5 Cable Entry Options

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4.4 Grounding Connection

Earth grounding connection is essential before connecting to the AC supply.
The positive DC busbar is connected to the grounding point in the rear of the system using

a copper bar.

1. Switch o all breakers on the distribution panel.

2. Connect an insulated cable with a cross-sectional area of 16mm² (5AWG) between the
earth connection point of the system and the Main Earth Terminal (MET).

3. Tighten the cable connection to a torque of 8 Nm.

Figure 4-6 Grounding Connection

If the Extended Rear and Top Cover Kit is installed on the power system, another earth
grounding point on the rear cover is supplied for convenient connection and cabling. Figure
4-7 below depicts how to connect the earth grounding cable to the rear cover.

Figure 4-7 Grounding Connection with Extended Rear Cover - Two Point

Manual No. MS0027-MAN rev. 4

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Figure 4-8 Grounding Connection with Extended Rear Cover - Single Point

4.5 AC Input Connection

WARNING Ensure that mains input is turned o before connecting. The grounding must

be connected to PE terminal as rst.

WARNING High leakage current. Ensure earth is connected before connecting mains
supply.

WARNING Only a qualied electrician may carry out the mains installation.

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, if not
delivered with the system..

WARNING Used cable must be inserted into the terminal with as little insulation removed
as possible, so as to prevents any stranded conductor coming loose and touching any other
conductive parts. Tighten terminals securely with torque 1.5-1.8Nm.

1. Strip the AC input cable conductors to the correct length for connection to the terminals.

2. Route the AC input cable through the AC cable entry and connect the cable to the AC
terminals and tighten the screws to 1.5 - 1.8 Nm.

3. The mains input terminal blocks can be connected to:

• 1-phase 110VAC or 230VAC (Figure 4-9)

• 3-phase 110/190VAC or 230/400VAC (Figure 4-10).

Manual No. MS0027-MAN rev. 4

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PE

PE

2.0 Nm + 10%

L2L3NIN2N3

LI

Figure 4-9 AC Input Terminal Block (1-phase)

Recommended mains breaker:

100-120VAC 1W+N+PE or 208-240VAC 1W+N+PE or 200-240VAC 2W+PE:

UL listed, Single pole 3 x 50A C-characteristics.

L3

L2

LI

2.0 Nm + 10%

Figure 4-10 AC Input Terminal Block (3-phase)

Recommended mains breaker:

360-416 V AC 3W+N+PE: UL listed,Three pole 50 A C-characteristics.

Manual No. MS0027-MAN rev. 4

Page 30

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PE

N3

N2

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4.6 DC Load Connection

Before connecting DC load cables, check that the cable rating is matched with selected the
MCB and/or load.

1. Check that all the load MCBs are in the OFF position.

2. Connect the negative (-) cable from the load to the relevant -48 V circuit breakers. Insert
the stripped cable into the opening on top of the terminal and tighten the screw to 3.0 Nm.

3. Connect the positive (+) cable from the load to the relevant positive terminal on the bus
bar. Insert the stripped cable into the opening on top of the terminal and tighten the screw
to 3.0 Nm.

4. The loads connected to the bus bar should be started from the left.

Figure 4-11 DC Load Connection

Load 0V

Load -48V

Manual No. MS0027-MAN rev. 4

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4.7 Battery Connection

The battery cables are not delivered with the system.

1. Check that all the battery MCBs are in the OFF position.

2. Connect the “+” cable of each battery string to the positive bus bar of the system. Tighten
the cable terminal to 3.0 Nm.

3. Connect the “-“cable of each battery string the battery circuit breaker. The copper bar
with washer and nut installed on the circuit breaker is used to connect and tighten the
battery cable lug.

4. Connect the other ends of the battery cables to the “-“and “+” terminals of the batteries.
Refer to Table 6-1 in the Maintenance and troubleshooting chapter for correct torque.

Battery 0V

Battery -48 V

Figure 4-12 Battery Connection

4.8 Alarm and Signal Connections

There are three kinds of alarm interface board for selection to meet the user’s requirement.

• PCC External Board: Select this if the PCC internal communication board is selected.

• ACC External Board: Select this if the ACC internal communication board is selected
and a maximum of 4 alarm relay outputs are required.

• ACC Relay Board: Select this if the ACC internal communication board is selected and
5 - 10 alarm relay outputs are required.

Manual No. MS0027-MAN rev. 4

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Blue

External Alarm Interface

(BM0723)

J1 Multi-purpose

26

J10

J2 Multi-purpose

J4 Temparature

J6 Alarm1

J7 Alarm2

J8 Alarm3

J9 Alarm 4

-24V

-36V

-12V

-24V

-36V

+5V

Sensor

0V

NO1

NC1

NO2

NC2

NO3

NC3

NO4

NC4

C2

C3

Figure 4-13 PCC External Board

Red

3-12V

Green

2
1

3
2

1

3
2
1

3
2
1

C1

3
2
1

3
2
1

3
2
1

C4

Blue

Red
Green
Blue

Symmetry #1

Temperature

sensor

1

Green

Red
Blue
Green

Red

Blue
Green

Red
Blue

Green

Red

Symmetry#1

Symmetry#2

Temperature

sensor

Temperature

sensor

+5V

+5V

2
3

4
5

6
7

8
9

10
11

12

0V

1
2

3
4

0V

5
6

3
2
1

6
5
4
3
2
1
6
5
4

XC2

Multi purpose 1-6

Multi purpose 7-12

XC3

TEMP1(BATT)

XC4

TEMP2(AMB)

Alarm 1

XC5

Digital In 1
Digital In 2
+5V

GND
Digital out 1

Digital out 2
+V

50

GND

XC1

XC7

XC8

XC6

Alarm 2

Alarm 3

Alarm 4

Figure 4-14 ACC External Board

Manual No. MS0027-MAN rev. 4

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Blue

+5V

+5V

1

Green

Red
Blue
Green

Red

Blue
Green

Red
Blue

Green

Red

Symmetry#1

Symmetry#2

Temperature

sensor

Temperature

sensor

2
3

4
5

6
7

8
9

10
11

12

0V

1
2

3
4

0V

5
6

3
2
1

6
5
4
3
2
1
6
5
4

1
2

K2

3

4
5

6
1
2

3
4
5

6

1
2

3
4
5

6

Digital In 1
Digital In 2
+5V

GND
Digital out 1

Digital out 2
+VR

50

8
8

GND

XC1
XC13

XC12

XC9

K1

K3

K4

K6

K5

XC7

XC8

Multi purpose 7-12

XC10

XC11

XC2

Multi purpose 1-6

XC3

TEMP1(BATT)

XC4

TEMP2(AMB)

Alarm 1

XC5

Alarm 2

Alarm 3

XC6

Alarm 4

Figure 4-15 ACC Relay Board

The alarm interface board is located in the top right side of the system. To connect the alarm
cable to the alarm interface board, follow the steps below:

1. Remove the green plug from each connector.

2. Determine whether to reference normally closed or normally open with reference to
common for each alarm contact.

3. Strip the wires back approximately 10mm. Stranded wire may be soldered or covered
with copper ferrule if desired.

4. Insert the wire into the top openings of the green plug and tighten the screw to clamp
wire.

5. Re-insert the green plug with the alarm cable into the alarm interface board.

NOTE The alarm conguration will be dependent on your system conguration.

NEED MORE INFORMATION? For detailed information regarding Alarm connection

see Appendix A, Installation Drawing.

Manual No. MS0027-MAN rev. 4

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4.9 Symmetry Connection

The ACC controller can supervise 4-block symmetry measurements on 4 battery branches. If
the PCC controller is used, only 2 battery branches can be measured on 4 blocks.

NOTE Symmetry cables are pre-connected to the system.

NOTE Multi Purpose inputs which are not used for symmetry measurement can be

recongured to user dened analog inputs.

1. Insert a suitably sized cable lug into one pole of the inter-block connection plate. Fasten
the lugs and plates to individual battery poles.

2. 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 4-16.

Figure 4-16 2-block Symmetry Measurement (for illustration only)

For 4-block measurement x the 3 wires (red, green and blue) of the symmetry cable to

individual cable lugs. Color coding of the cables must be followed for proper symmetry
measurement, see Figure 4-17.

Figure 4-17 4-Block Symmetry Measurement (for illustration only)

Manual No. MS0027-MAN rev. 4

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Temp. Sensor

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

4.10 Temperature Sensor Connection

NOTE The power system is usually delivered with pre-connected temperature sensor
cables. If not, use a three-pin plug and connect according to the Appendix A - Installation

Details.

Battery Temperature

Temperature sensor 1 measures the temperature of the battery bank while the controller

adjusts the oat charge voltage according to the temperature compensation factor set in the

controller. This factor must be set in the controller according to the battery manufacturer ‘s
recommendations.

Fasten the temperature sensor in the middle of the battery bank, Figure 4-18.

Figure 4-18 Temperature Sensor Connection

NOTE The temperature compensation factor can be set only for temperature sensor 1.

Ambient Temperature

Temperature sensor 2 allows a second temperature reading, most commonly the ambient
temperature around the system. Place the sensor as required.

The temperature is displayed in the External Measurements menu in the ACC controller or
in PowCom™ software.

NOTE Temperature sensor 2 can be activated only in the systems with the ACC
controller installed.

Manual No. MS0027-MAN rev. 4

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4.11 Connecting an RS232 Communication Cable

The controller can communicate with an external device such as a network interface card
through an RS232 connection.

1. Remove the top cover of the controller.

2. Connect the RJ45 port of the RS232 communication cable to the RJ45 port marked with
RS232 on the internal communication board.

3. Pull out and x the DB-9 connector of the RS232 communication cable for application.

4. Re-install the top cover of controller.

A

DETAIL A

Figure 4-19 RS232 Connection

4.12 Rectier Installation

NOTE Ensure that the rectier handle is in the OPEN position (forms 35-40° angle with

rectier body) before inserting the module into the slot.

Rectier module should be installed starting from the bottom left position in the rectier

shelf.

NOTE If you ordered a power system with 3 rectier positions, leave the bottom two

slots blank and install the rectier from the middle left position.

1. Place the rectier module in the mounting slot with handle facing out.

2. Slide the rectier module into the slot until it contacts the interface connection at the rear
of the shelf, Figure 4-20 #1.

Manual No. MS0027-MAN rev. 4

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1

3. Fully insert the rectier by pushing the handle towards the shelf. The rectier handle will

rise up and lock the rectier into the position, Figure 4-20 #2.

4. Repeat steps 1 to 3 if more rectiers are to be installed.

2

Figure 4-20 Rectier Installation

4.13 Reinstalling Top Cover

After completing all connections, reinstall the top cover if the Rear and Top Cover Kit is
ordered.

1. Place the top cover on the top of the Distribution Unit. Make sure that the to cover and
Distribution Unit are matched well.

2. Install the front panel of Distribution Unit so that the top cover is xed and unremovable.

3. If the Extended Rear and Top Cover Kit is ordered, reinstall the AC input cover on the
back of the unit.

Manual No. MS0027-MAN rev. 4

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Chapter 5 Commissioning

5.1 Commissioning Overview

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

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

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

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

adjusted to a lower level.

5.2 Tools and Test Equipment

5.2.1 Tools List

The essential commissioning tools are listed in the Installation chapter.

5.2.2 Test Equipment

• Multimeter (3½ Digit, 0–1%DC)

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

5.3 Preparation

Check the installation to ensure the following:

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

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

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

Manual No. MS0027-MAN rev. 4

Page 39

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POWERING TECHNOLOGY

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

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

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

13. Set the battery current limit according to the battery manufacturers requirements.

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. MS0027-MAN rev. 4

Page 40

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5.5 Test of output voltage

5.5.1 Float charge (U1)

Ensure that the controller is operating.
Connect a load, approx. 50% of total capacity, to the system.
Check the voltage according to the battery manufacturer’s requirements. If the batteries

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

the section for the appropriate controller)
If no change is required, use the following values:

Battery type Float charge Boost charge

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

Table 5-1 Float/Boost Charge Voltages

5.5.2 Adjustment of Float Charge, U1

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

Please verify number of cells and the battery manufacturers requirement.
Adjust the output voltage from the control unit as necessary.

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. MS0027-MAN rev. 4

Page 41

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POWERING TECHNOLOGY

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. MS0027-MAN rev. 4

Page 42

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POWERING TECHNOLOGY

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. MS0027-MAN rev. 4

Table 5-2 Commissioning Record

Page 43

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Chapter 6 Maintenance & Troubleshooting

6.1 Maintenance

6.1.1 Checking Terminal Connection

The connections on the terminal blocks and circuit breakers must be checked according to
the Table 6-1 at least once a year.

TYPE OF CONNECTION MODEL / DESCRIPTION TORQUE

(Nm)

Terminal block for rail AKG 16mm² 2.5 22
Terminal block for rail AKG 35mm² 3.5 31
Front terminal for copper cables FC Cu T2 95mm² 7.0 62
Terminal block Weidemullers WDU 4mm 0.6 5
Terminal block Weidemullers WDU 10mm 2.0 18
Terminal block Weidemullers WDU 16mm 3.0 27
Miniature circuit breaker Siemens 2.5 22
Miniature circuit breaker Merlin G 3.5 31
Miniature circuit breaker ABB 2.0 18
Miniature circuit breaker CBI HY-MAG 3.0 27
Molded case circuit breaker ABB 160A - S2 5.0 45
Molded case circuit breaker ABB 160A/250A - S3/S4 9.0 80
Molded case circuit breaker ABB 630A - S6 9.0 80
Molded case circuit breaker Terasaki - XS125CJ 9.0 80
Connection unit for 2 or 3 pole breaker Merlin G & Siemens 13.5 120
Terminal Block Phoenix Phoenix Mini Combicon 0.25 2
Terminal block Phoenix UK10 / UKLKG10 1.5-1.8 13-16
Terminal block Phoenix UK16 / USLKG16 1.5-1.8 13-16
Terminal block Phoenix UK35/UIK35/USKG35/UISKG35 3.2-3.7 28-33
Miniature circuit breaker Nadar 2.5 22

TORQUE
(Inch LB)

Table 6-1 Connection Torque Setting Check

6.1.2 Other Requirements

At least once a year the output voltage should be veried to be within acceptable limits. The
result of the test should be recorded and led to see any deviations.

In addition, the system requires periodic inspections and routine cleaning. It is very important
to keep the 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.

Manual No. MS0027-MAN rev. 4

Page 44

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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

Module failure.

Replace faulty module.

Voltage

High System

Loss of AC power.
Load exceeds module capacity.

Module failure.

Verify AC input connection.
Add module to system.

Replace the faulty module.

Voltage

System voltage exceeds the set limit.

Check the High Voltage Alarm limit
setting.

Mains Error

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

AC supply OFF on at least two

Verify that the AC input breaker is
ON.

Verify AC input connection.

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

AC Low V oltage

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

setting.
Verify AC Input connection.
Verify AC Input voltage.

AC High

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

Voltage

Verify the AC Input voltage.

Manual No. MS0027-MAN rev. 4

Page 45

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Fault Possible Cause Suggestion/Solution
Module Failure

Faulty module.

Check if module sends alarm ag.

Urgent Module
Failure

High Load

Overvoltage
Shutdown

Load/Battery
Disconnection

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

Rectier current sharing fault.

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.

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.

Manual No. MS0027-MAN rev. 4

Page 46

Check the rectier modules.

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Fault Possible Cause Suggestion/Solution
Communication

Failure

Module failure.

Check the non-communicating
address

Modules not installed in the correct
position.

If the rectier address does not

communicate re-install the module

Broken or disconnected

and wait for 5 minutes.

communication wire.

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

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

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

Distribution
Fuse Failure

Battery Fuse
Failure

Tripped load breaker / blown load
fuse.

Tripped load breaker / blown load
fuse

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

Verify there is no short circuit in load
cabling.

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

Replace the breaker / fuse if
necessary.

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

Verify the breaker / fuse is correctly
rated.

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

Replace the breaker / fuse if
necessary.

Manual No. MS0027-MAN rev. 4

Page 47

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Fault Possible Cause Suggestion/Solution
Symmetry Fault

Battery at end of life.

Verify the battery condition.

Low Battery
Temperature

high Battery
Temperature

Temp. Probe
Failure

Alarms Blocked
(only with LCD
display)

Wrong symmetry cable connection.
Wrongly set Symmetry limit value.

Battery temperature drops below the
set Low battery temperature limit.

Battery temperature exceeded the set
limit.

The temperature probe is not properly
connected to the system.

Faulty temperature probe.
Temperature probe wire is

interrupted.

Temperature dierence between the

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

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

Verify the symmetry cable
connection.

Verify the Symmetry limit value.
Check the heating of the system.

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

Check the cooling or ventilation.
Verify the battery condition.
Check the Battery Current Limit.

Verify the temperature probe
connection.

Verify the internal / external
temperature via controller front panel.

Replace the faulty probe with a new
one.

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

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

If none of the above solves the problem please contact customer support.
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. MS0027-MAN rev. 4

Page 48

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1

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, Figure 7-1 (1).

1

2

Figure 7-1 Unlocking and Removing the Controller

2. Pull the controller out of the shelf, Figure 7-1 (2).

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

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

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

7.2 Rectier Replacement

NOTE Rectiers can be hot-swapped.

This section describes how to replace a faulty rectier in an active system.

1. Release the rectier handles and remove the faulty rectier.

2. Insert the new rectier into the slot and fasten it with the handles. Refer to section 4.12
of this manual for details.

3. Ignore the module alarm caused by current sharing.

4. After 1 minute the yellow LED starts blinking. Wait for a maximum of 4 minutes for the
indicator to stop blinking.

Manual No. MS0027-MAN rev. 4

Page 49

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7.3 Battery and Load Breakers Replacement

WARNING Make sure the system is switched OFF.

The power rack is designed front accessible for easy maintenance. Battery and load breakers
can be replaced without removing the power rack from the cabinet.

This section describes how to replace faulty breakers.

1. Remove the front panel and the top cover as described in section 4.3.1.

2. Pull out the faulty breaker(s).

3. Install the correct breakers

4. Replace the front panel and the top cover as described in section 4.13.

7.4 Surge Protection Device Replacement

This section describes how to replace a faulty surge protection module.

1. Switch o AC input power.

2. Remove the top cover if the Rear and Top Cover Kit is installed.

3. Unscrew the retaining screw (1) and pull out the alarm interface board kit (2).

4. Pull out the failed surge protection module(3).

11

3

2

Figure 7-2 Replacing a Surge Protection Module

5. Insert a new surge protection module into the corresponding position.

6. Reinstall the alarm interface board kit and fasten the retaining screw.

7. Reinstall the top cover of power system.

8. Switch on AC input power.

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. MS0027-MAN rev. 4

Page 50

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System Layout

Dimensions: 3U x 19"

LVD:

RS232 CONNECTION

(REMOVE TOP COVER

LVBD & LVLD CONTACTORS

CONNECTIONS

A.1 System Layout

Appendix A - Drawings

200A 48V (for 5 pos system)OR125A 48V (for 3 pos systems)

OR

Dummy LVD kits

CONTROLLER:

ACC or PCC (w/ethernet) with Display

RECTIFIERS:

5 x Guardain 48V (for 5 pos system)OR3 x Guardian 48V (for 3 pos system)

PLD:

125A 48V

AC Distribution:

3-phase 3+1, Class C SPD optional

DC Distribution:

Min. LPHP/LPHP

LP

Batt 1 123456789 10 11 12 13

1 x single pole battery breaker

13mm load breakers

Six configurations optional

Min. LPHP/LPHP

LP

Min. LPHP/LPHP

LP

Min. LPHP/LPHP

LP

Min. LPHP/LPHP

LP

Min. LPHP/LPHP

LP

1 2 3 4 5 6

Batt 3

123456789

Batt 1

1 x single pole battery breaker

Batt 1 Batt 2 123456789 10 11

18mm load breakers

2 x single pole battery breakers

13mm load breakers

Batt 1 Batt 2 12345678

2 x single pole battery breakers

Batt 1 Batt 2 Batt 3 1 2 3 4 5 6 7 8 9

18mm load breakers

3 x single pole battery breakers

Batt 2

Batt 1

13mm load breakers

3 x single pole battery breakers

18mm load breakers

LOAD BREAKERS

(6 x 18mm configuration shown)

CONTROLLER

USB ETHERNET

Manual No. MS0027-MAN rev. 4

GUARDIAN 48

ALARM & SIGNAL

CONNECTIONS

(see manual for details)

CONNECTIONS

LOAD & BATTERY

BATTERY

FB1 FB2 FB3 F1 F2 F3 F4 F5 F6

BREAKERS

GUARDIAN 48 GUARDIAN 48

SURGE SUPPRESSOR

(optional)

USB & ETHERNET

GUARDIAN 48

GUARDIAN 48

RECTIFIERS

AC CONNECTIONS

FOR ACCESS)

Page 51

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A.2 Installation Details - Connections

Symmetry cable connections

Table shows different ways of battery symmetry cable connections depending on actual software (see controller software sheet)

Battery type: 2 blocks

White

0V

-12V

-24V

-36V

-48V

White

(-)24V

Battery symmetry 3
Battery symmetry 2

XC2

Battery symmetry 1

Battery
string2.

0V

(-)24V

-12V

-24V

-36V

-48V

Battery
string1.

Battery
string2.

Battery type: 4 blocks

0V

-12V

Battery

-24V

string1.

0V

-12V

-24V

-36V

-48V

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

-36V

-48V

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

red

green

blue
red

green

blue

Battery symmetry 3
Battery symmetry 2

XC2

Battery symmetry 1
Battery symmetry 6

Battery symmetry 5
Battery symmetry 4

Input mains terminals

single phase 120/230VAC

1 2 3 4 5 6 7

1

N LPE

PE

2-phase 240VAC (N.A. / CALA)

1 2 3 4 5 6 7

1

L1PE

PE

L2

3-phase 208/230VAC

(∆ connection)

1 2 3 4 5 6 7

L2 L3

L1PE

3-phase 400VAC

( Y connection)

1 2 3 4 5 6 7

N L1 L2 L3PE

ACC Standard Alarm interface

Multi purpo

XC2

Multi purpose 2

Multi purpose 1
Multi purpose 6

Multi purpose 5

XC2

Multi purpose 4
Multi purpose 9
Multi purpose 8

XC3

Multi purpose 7
Multi purpose 12

Multi purpose 11

XC3

Multi purpose 10

Temperature

sensor

Temperature

sensor

Alarm contacts

are shown in

alarm position

XC4

XC4

XC5

XC5

XC6

XC6

XC7

XC8

Battery
Temperature

Ambient
Temperature

Alarm 1

Alarm 2

Alarm 3

Alarm 4

GND
+5V

Digital Input 2
Digital Input 1

-Sys. Voltage Out

+Sys. Voltage Out

Digital Output 2
Digital Output 1

se 3

Manual No. MS0027-MAN rev. 4

Page 52

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A.3 Block Diagram

shunt

LVD

Optional PLD

0V

- Load 1

- Load n

- PLD Load 1

- PLD Load n

- Battery 1

- Battery n

9

J2

Ethernet

USB

ACC

8

J1

+

Subrack for

2xRectifier

Rectifier Rectifier

96

J3

-

Rectifier Rectifier

96

+ -

Subrack for

2xRectifier

8

J2
J1

ACC internal board

1 0V

XC3 System voltage in

2 -48V

XC7 RS485

1

XC5 Door alarm

2
1

XC6 Surge arrestor alarm

2

1 shunt­2 shunt+

3 bat alarm

4 load alarm
5 LVD disconnect
6 LVD reconnect

11 PLD disconnect
12 PLD reconnect

XC1

Rectifier

Fuse alarm board(9948)

8

XC10

8

XC8

XC9-A

XC2

XC9-B

XC4

System voltage out

+

Subrack for

1xRectifier

-

CAN

RS232

50

ACC external board

Multi purpose 1-6

XC1

Multi purpose 7-12

Digital In 1
Digital In 2
+5V
GND

Digital out 1

Digital out 2
+V

GND

1
2

XC2

3
4
5
6
7
8

XC3

9
10
11
12

3

+5V

XC4

2

Sense

Temp. 1

1

0V

3

Alarm 1

Alarm 2

Alarm 3

Alarm 4

2
1

3
2
1

3
2
1

3
2
1

XC7

XC5

XC8

XC6

Surge protection module

Manual No. MS0027-MAN rev. 4

L1 L2

L3 N

N N PEPE

Page 53

Applicable for 5 POS system

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4 x Ø 0.25 (6.3) [6Nm max. torgue]

0.10 ±0.01 (2.5 ±0.2)

15.02 ±0.02 (381.4±0.5)

A.4 Detailed Dimensions

14.43 ±0.02 (366.4±0.5)

13.64 ±0.02 (346.4±0.5)

8 x PEM S-M4-2 ZI or equiv. [both sides]

19.07 (454.3)

16.04 (407.5)

15.65 ±0.02 (397.4 ±0.5)

15.59 ±0.02 (395.9 ±0.5)

7.54 ±0.02 (191.4±0.5)

6.75 ±0.02 (171.4±0.5)

11.78 ±0.02 (299.2 ±0.5)

11.14 ±0.02 (282.9 ±0.5)

4 x PEM S-M4-2 ZI or equiv.
[both sides]

0.8 ±0.01

(20 ±0.3)

Extended Top/Rear Cover

(92.5 ±0.3)

3.64 ±0.01

1.48 ±0.01

(37.7±0.3)

Dimensions: in. (mm)

5.22 ±0.01

(132.5 ±0.3)

2.25 ±0.01

(57.1±0.3)

Note: Extended Cover details are shown in green.

GUARDIAN 48

19.00 ±0.03 (482.5±0.8)

17.64 ±0.03 (443.5±0.8)

17.38 ±0.03 (441.5±0.8)

18.31 ±0.03 (465.0±0.8)

GUARDIAN 48 GUARDIAN 48

GUARDIAN 48

GUARDIAN 48

FB1 FB2 FB3 F1 F2 F3 F4 F5 F6

Manual No. MS0027-MAN rev. 4

Page 54

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