Unipower XPGe12.48, XR08.48, XR04.48 Instruction Manual

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POWERING TECHNOLOGY

Power Supply System

Aspiro 2U Front Access

Instruction Manual

Document Number: ASPIRO2U-3

aspiro2u_m23-man-rev3-0516.indd

www.unipowerco.com

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

North America: +1 954-905-1071 • Latin America: +1 954-905-1078 • Europe: +44 1903 768200

POWERING TECHNOLOGY

subparagraph © (1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS

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

For Contact Information, please go to http://www.unipowerco.com/contact/ Refer to the UNIPOWER License Agreement in this package before installing or using this product.

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

solely to illustrate the use of UNIPOWER products. Product names, logos, brands, and other trademarks featured or referred to within this product

manual are the property of their respective trademark holders. These trademark holders are not

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

LIMIT ATIONS AND AUTHORIZA TIONS FOR USE AND PERMITTED APPLICA TIONS UNIPOWER’s products are not designed, intended for use in, or authorized for use as critical

components in, human life support systems/equipment, equipment used in hazardous environments, or equipment used in nuclear control equipment or systems. Any such use requires the prior

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

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

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

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

September 2015

Manual No. aspiro2u-3

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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

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

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

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

2.2 System Parameters ..................................................................................................................9

2.3 System Components..............................................................................................................11

2.3.1 System Controller ........................................................................................................11

2.3.2 DC Distribution Unit....................................................................................................11

2.3.3 Rectier Module ..........................................................................................................12

Chapter 3 System Safety..............................................................................................................13

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

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

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

3.1.3 Installation W arning .....................................................................................................14

3.1.4 Restricted Access Area W arnings.................................................................................14

3.1.5 System Enclosure .........................................................................................................14

3.1.6 Operating Temperature Warnings ................................................................................14

3.1.7 Electrical Safety Warnings ...........................................................................................15

3.1.8 Grounding ....................................................................................................................16

3.1.9 Batteries .......................................................................................................................16

3.1.9.1 Lead Acid Batteries ..........................................................................................16

3.1.10 In Case of an Accident ...............................................................................................17

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

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

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

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

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

3.2.5 Breakers .......................................................................................................................18

3.2.6 Hot Surfaces .................................................................................................................18

Chapter 4 Installation Guide ......................................................................................................19

4.1 Unpacking .............................................................................................................................19

4.2 T ools ......................................................................................................................................19

4.3 Rack Mounting ......................................................................................................................19

4.4 Cable Entry ...........................................................................................................................21

4.6 AC Input Connection ............................................................................................................22

4.7 DC Load Connection ............................................................................................................23

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4.8 Battery Connection ...............................................................................................................24

4.9 Alarm and Signal Connections ..............................................................................................25

4.10 Symmetry Connection ........................................................................................................26

4.11 Temperature Sensor Connection .........................................................................................27

4.12 Rectier Installation ............................................................................................................28

4.13 Connection of External PDU to DC Parallel Kit (Option) .................................................29

4.14 Reinstalling Top Cover .......................................................................................................29

Chapter 5 Commissioning ...........................................................................................................30

5.1 Commissioning Overview ....................................................................................................30

5.2 T ools and Test Equipment .....................................................................................................30

5.2.1 T ools List ......................................................................................................................30

5.2.2 T est Equipment ............................................................................................................30

5.3 Preparation ............................................................................................................................30

5.4 Commissioning procedure ....................................................................................................31

5.5 Test of output voltage ............................................................................................................32

5.5.1 Float charge (U1) .........................................................................................................32

5.5.2 Adjustment of Float Charge, U1 ..................................................................................32

5.5.3 Boost charging (U2) (if applicable) .............................................................................32

5.6 Battery supervision ...............................................................................................................33

5.7 Battery test ............................................................................................................................33

5.8 Commissioning record ..........................................................................................................34

Chapter 6 Maintenance & Troubleshooting ..............................................................................35

6.1 Maintenance ..........................................................................................................................35

6.1.1 Checking Terminal Connection .........................................................................................35

6.2 Troubleshooting ....................................................................................................................35

Chapter 7 Replacing Modules .....................................................................................................40

7.1 Controller Replacement ........................................................................................................40

7.2 Rectier Replacement ...........................................................................................................41

7.2.1 XR04.48 / XR08.48 Replacement ...............................................................................41

7.2.2 XPGe12.48 Replacement .............................................................................................41

7.3 Battery and Load Breakers Replacement ..............................................................................42

7.4 Surge Protection Device Replacement ..................................................................................44

7.5 Other Requirements ..............................................................................................................44

Appendix A - Drawings

................................................................................................................45

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FIGURES

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

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

Figure 4-1 System Mounting ......................................................................................................20

Figure 4-2 Slide Bracket Fixing .................................................................................................20

Figure 4-3 System Bracket Fixing ..............................................................................................21

Figure 4-4 System With Cover Removed ...................................................................................21

Figure 4-5 Grounding Connection ..............................................................................................22

Figure 4-6 AC Input Terminal Block (1-phase) ..........................................................................23

Figure 4-7 AC Connection Options ............................................................................................23

Figure 4-8 DC Load Connection ................................................................................................24

Figure 4-9 Battery Connection ...................................................................................................25

Figure 4-10 Alarm Connections ...................................................................................................25

Figure 4-11 2-block Symmetry Measurement (for illustration only) ...........................................26

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

Figure 4-13 Temperature Sensor Connection ...............................................................................27

Figure 4-14 Rectier Installation ..................................................................................................28

Figure 4-15 External PDU Connection .........................................................................................29

Figure 4-16 DC Parallel Principle ................................................................................................29

Figure 7-1 Unlocking the Controller ..........................................................................................40

Figure 7-2 Removing the Controller ...........................................................................................40

Figure 7-3 Replacing an XR04.48 or XR08.48 Rectier ...........................................................41

Figure 7-4 Replacing an XPGe12.48 Rectier ...........................................................................42

Figure 7-5 Removing the front panel ..........................................................................................42

Figure 7-6 Removing the top cover ............................................................................................43

Figure 7-7 Pulling out a faulty breaker .......................................................................................43

TABLES

Table 5-1 Float/Boost Charge Voltages .....................................................................................32

Table 5-2 Commissioning Record .............................................................................................34

Table 6-1 Connection Torque Setting Check ............................................................................35

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Chapter 1 About This Manual

1. About This Manual

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

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

cautions and noteworthy information.

1.1 Objectives

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

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

1.2 Audience

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

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

1.3 Document Key

This manual uses the following conventions:

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

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

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

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

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T able 1-1 Abbreviations

Abbreviation Description

PCC Prime Controller Card ACC Advance Controller Card LVD Low Voltage Disconnection PLD Partial Load Disconnection (load shedding) XR04.48 400 W Rectier XR08.48 800 W Rectier XPGe12.48 1200 W Rectier DB22 Distribution Drawer (4 x load, 1 x battery) D22 Distribution Drawer (3 x load) D33 Distribution Drawer 2 x load) B33 Distribution Drawer (2 x battery)

1.4 Feedback & Support

For technical support or feedback, please visit http://www.unipowerco.com/contact/ and select Customer “Support/Repairs” and then “Customer Service”.

Alternatively, email: sales@unipowerco.com

1.5 Layout, Numbering and Printing

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

1.6 Disclaimer

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

modication of the instructions provided in this manual.

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Chapter 2 Aspiro System Description

2.1 Overview

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

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

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

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

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

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

immediate rectier status indication.

The Power system is highly congurable with installed capacity from 400W up to 4800W

together with DC distribution, system controller and battery backup. The power system can be managed locally through messages and alarm displayed on the

LCD screen of the system controller or remotely, using the PC-based PowCom™ software, or through a web browser with Ethernet connection.

Aspiro 2U system consists of:

1. System Controller ACC Extended

2. Load Distribution Unit

3. Alarm Interface Module

4. AC Input Terminal Block

5. Internal Connection Board

6. AC Surge Protection Device (Option)

7. Rectier Module

8. Battery Distribution Unit

Manual No. aspiro2u-3

Figure 2-1 Power System Overview

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2.2 System Parameters

OUTPUT

Power (max) 4800W (XPGe12.48G), 3200W (XR08.48G), 1600W (XR04.48G) Output Current (max) 60A @ 55°C (XPGe12.48G & XR08.48G)

30A @ 55°C (XR04.48G)

Voltage 46-57VDC

INPUT

Voltage 1-phase 100-120/200-240VAC (L + N + PE)

3-phase 230/400VAC (L1 L2 L3 + N + PE) Frequency 47-63Hz Input Current 1-phase 32A @ 100-120VAC, 14A @ 200-240VAC

3-phase 8A per phase @ 230/400VAC Power factor >0.98 Surge Protection Optional

DC DISTRIBUTION & BATTERY MANAGEMENT

Battery Breakers 2 x 30A, 45A, 60A, 80A or 100A Symmetry Inputs Up to 6 Programmable LVD / PLD 125A (voltage) / 125A (voltage/time) Load Breakers 8 x (NADER NDB3 Series) Ratings* 1A, 4A, 5A, 7.5A, 10A, 15A, 20A, 25A, 30A

MONITORING AND CONTROL

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

Yellow LED - Message(s)

Red LED - Alarm(s) Analog Inputs 12 x voltage inputs (range 0-100VDC) - 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 M6 lugs, +Ve common from bus bar AC connections Max. 9AWG/6mm

, 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

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RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48

E󰀩ciency 95% typical @ I

nom 90% typical @ I

out

nom 88% typical @ I

out

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

22.4A 15.0A 7.5A

53.5V oat

Output Power 1200W @ >180VAC

800W 400W

750W @ 90-180VAC

Operating Temperature

55°C 65°C 65°C

(without derating) Input Voltage

90-300VAC 85-300VAC

(Nominal 100-240VAC) Output Voltage 46-57VDC Load sharing < 5% of nominal current Dimensions (WxHxD) 40.6 (1.6”) x 101.62(4”) x 228.5(9”) mm Weight 1.1 kg Cooling Fan-cooled, speed and alarm controlled, air ow direction rear to front Protection Short circuit proof, automatic current limiting, selective shutdown of modules

at excessive output voltage. Alarms High output voltage/ shutdown, Low voltage/ module failure LED Indication

Green: Power ON Yellow: Current limit/ thermal protection Fan failure / Over temperature Pre-warning / thermal protection Communication Failure (ashing) Red: Module failure / high output voltage shutdown

Audible noise <55dBA according to ISO7779

MECHANICAL

Dimensions (WxHxD) 19” (483mm) x 3.5” (88mm) x 11.7” (297mm) Weight of the system

32lbs (14.5kg)

(fully equipped) Mounting Options 19”/ ETSI / Mid-mount Cable Entry Rear Access (top cover has to be removed to make connections)

STANDARD COMPLIANCE / ENVIRONMENTAL

EMC and Immunity EN55022:2006 +A1:2007, EN55024:1998 +A1:2001 +A2:2003,

EN61000-3-2:2006+A1:2009 +A2:20009, EN61000-3-3:2008

ETSI EN300386 V1.4.1 Safety EN60950-1: 2006 + A11:2009 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

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2.3 System Components

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

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

2.3.1 System Controller

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

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

2.3.2 DC Distribution Unit

The distribution unit can be congured for a variety of pluggable battery and load breaker

selections, a shunt for battery current measurement and fuse alarms for load and battery breakers. The front access enables easy replacement of breakers and fuses if needed.

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

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

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

2.3.2.1 Low Voltage Disconnect (LVD)

The system is equipped with low voltage battery disconnection, which prevents the batteries from deep discharging, thus prolonging the battery life. The disconnection requires detected mains failure at the controller . If disconnection occurs, the batteries are reconnected when the mains supply is restored.

A maximum of two breakers with current rating maximum 100A can be installed.

2.3.2.2 Partial Load Disconnection / Load Shedding (PLD)

During a mains outage the controller opens the PLD contactor when the batteries have discharged down 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.

A maximum of seven breakers with current rating maximum 30A can be installed.

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2.3.3 Rectier Module

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

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

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

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

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

information to the controller.

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

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

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

voltage by the controller.

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

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

XR08.48 rectiers.

Manual No. aspiro2u-3

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

Page 12

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Chapter 3 System Safety

3.1 Safety Warnings and Guidelines

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

3.1.1 System Markings

The following markings are found on the Power System:

Ground Symbol

DC Ground Symbol

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

ratings and safety approvals. The label is located 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.

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3.1.3 Installation Warning

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

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

• The system 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.

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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.

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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.

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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.

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3.2.5 Breakers

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

3.2.6 Hot Surfaces

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

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Chapter 4 Installation Guide

4.1 Unpacking

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

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

4.2 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.

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

4.3 Rack Mounting

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

The power system is designed for 19”/ETSI mounting to a cabinet or an open frame. The

mounting brackets on the sides of the power system t the chassis in three dierent positions

for various mounting depth. See appendix A for detailed dimensional Drawings.

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2.7 (68)

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 the subrack measurement. If necessary,

x the mounting bracket in a dierent position, see Figure 4-1. (The default position of

mounting brackets is 19” rack width, front mount.)

FIXED

BRACKETS

2.7 (68)

SLIDE

BRACKETS

3.9 (99)

1.2 (31)

10.2 (260)

2.7 (68)

Figure 4-1 System Mounting

2. Place the subrack into the cabinet.

3. The subrack with adjustable brackets has to be fastened to the cabinet in the middle of the mounting bracket with two M6 x 12mm screws. Tighten the screws to 6Nm, Figure 4-2.

Manual No. aspiro2u-3

Figure 4-2 Slide Bracket Fixing

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4. Then fasten the subrack, either with adjustable or xed brackets, to the cabinet with four M6 x 12mm (2 on each side of the subrack). Tighten the screws to 6Nm, Figure 4-3.

Figure 4-3 System Bracket Fixing

4.4 Cable Entry

If the top distribution cover is installed, it should be removed for connecting AC, DC, alarm, grounding, temperature and symmetry measurement cables.

Push the top cover backwards and then lift it to remove.

Manual No. aspiro2u-3

Figure 4-4 System With Cover Removed

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4.5 Grounding Connection

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

safe and ecient operation, see Figure 4-5.

Figure 4-5 Grounding Connection

4.6 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.

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.

T o connect, route the AC input cable through the cable entry and connect to the AC terminals.

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3x400VAC

1x230VAC

2x230VAC

(US Install Reference)

Figure 4-6 AC Input Terminal Block (1-phase)

The mains input terminal blocks can be connected to: 3-phase 400VAC, 1-phase230 VAC or 2-phase 230VAC, see Figure 4-7.

6655443322111

N/L2

6 5 4 3 2 1 17

Figure 4-7 AC Connection Options

Recommended AC mains breaker:

400VAC 3-phase: UL listed, triple pole 20A C-characteristic 230VAC 1-phase: UL listed, double pole 40A C-characteristic

4.7 DC Load Connection

Before connecting DC load cables, check the appropriate cable ratings. Maximum cable size is 9AWG/6.0mm².

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

2. Connect the negative (-) DC cable to the relevant circuit breaker.

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• Insert a at screw driver into the square hole of green spring terminal to compress the spring.

• Push the stripped cable into the round hole of the same terminal.

• Take out the screw driver to clamp the cable in the correct position.

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 2.5Nm. See gure 4-8

Load 0V Load -48V

Figure 4-8 DC Load Connection

4.8 Battery Connection

The battery cables are not delivered with the subrack system. Check that all the battery MCBs are in the OFF position. Connect the (-) battery cable of each battery string to the copper bar with the screw. T ighten

the cable to a torque 4.0Nm. Connect the (+) battery cable of each battery string to the positive bus bar of the subrack.

Tighten the cable terminal to 3.5Nm. See gure 4-9

Connect the other ends of the battery cables to the (-) and (+) terminals of the batteries. Refer to Table 6-1 for correct torque.

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Battery -48 V Battery 0V

Figure 4-9 Battery Connection

4.9 Alarm and Signal Connections

For remote supervision of the alarms, there are a maximum 4 potential free alarm contacts

available. Each alarm contact represents dierent alarm condition, dependent on system conguration.

The alarm connections are located on the top right side of the subrack on the Alarm Interface. Use suitably sized alarm cables: Max. 14AWG/1.5mm². The Connection of all alarms are shown in Figure 4-10.

NC C

NO NC C

Figure 4-10 Alarm Connections

2 1

6 5

4 3

2 1

6 5

Alarm

NOTE Alarm contacts are shown in alarm position.

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To connect the alarm cables to 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 tted with a copper ferrule if desired.

4. Insert wire into the correct positions in the green connector and tighten the screw to clamp the wire.

5. Insert the green plug back into the Alarm Interface board.

4.10 Symmetry Connection

NOTE Symmetry cables are pre-connected to the system.

1. Attach the interblock connection plates between the batteries.

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

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

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

4. 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 4-12.

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Temp. Sensor

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

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

4.11 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 4-13.

Manual No. aspiro2u-3

Figure 4-13 Temperature Sensor Connection

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XR04.48 & XR08.48 XPGe12.48

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.

4.12 Rectier Installation

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

shelf.

Rectier Installation:

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.

3. a) For XR04.48/XR08.48 fully insert the rectier by pushing it into the shelf, fasten the

rectier in the slot and tighten the screw with a screw driver.

b) For XPGe12.48 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 position.

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.

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

Manual No. aspiro2u-3

Figure 4-14 Rectier Installation

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ALARM CONNECTOR

Connection Busbar

4.13 Connection of External PDU to DC Parallel Kit (Option)

1. Turn OFF all the breakers and the AC input before installation.

2. Connect the vertical cable DC parallel cable lug to the positive and negative bus bar with two M5 x 16mm screws.

3. Connect the external PDU load breaker alarm cable to pin1 of alarm terminal block.

DC Parallel

Load 0V Load -48V

FUSE/BREAKER

Figure 4-15 External PDU Connection

External PDU

Fuse Alarm

-48VDC 0VDC

Fuse Alarm

Board

Load Breakers

Figure 4-16 DC Parallel Principle

4.14 Reinstalling Top Cover

When all connections are done reinstall the Top and Rear Cover Kits if ordered. Place the top cover on top of the Distribution Unit. Make sure that the top cover and

Distribution Unit t tightly.

Install the front panel of the Distribution Unit to make the top cover xed and irremovable.

If the Extension Rear and T op Cover Kits are ordered, reinstall the AC input cover at the back of the unit.

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Chapter 5 Commissioning

5.1 Commissioning Overview

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

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

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

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

adjusted to a lower level.

5.2 Tools and Test Equipment

5.2.1 Tools List

The essential commissioning tools are listed in the Installation chapter.

5.2.2 Test Equipment

• Multimeter (3½ Digit, 0–1%DC)

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

5.3 Preparation

Check the installation to ensure the following:

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

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

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

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5.4 Commissioning procedure

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

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

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

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

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

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

6. Turn on the AC mains voltage.

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

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

8. Plug in all rectier modules, starting from the leftmost position. Make sure to fasten the

rectiers again. The rectiers will turn on automatically.

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

10. 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).

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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.

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Boost charging gures

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

from control unit or PC with PowCom™ installed.

5.6 Battery supervision

For systems with symmetry cables supplied:

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

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

For systems with temp. probe cable supplied:

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™.

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5.8 Commissioning record

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

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

position and that no rectiers are mounted in the

subrack(s).

3 Connect AC, and measure voltage on the mains

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

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

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

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

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

7 Check temperature compensation. It is to be

adjusted according to the battery manufacture requirements.

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

8 Check symmetry measurement and set number

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

9 Check alarm transmission by running an alarm

test.

Checked

()

Result

L1-N:……….V AC

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

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

U1:…….V DC

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

Comp.:…….V/10°C

Read o:………°C

Number: …. Alarm limit:……

Manual No. aspiro2u-3

Table 5-2 Commissioning Record

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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)

0 V Load AKG 5AWG/16mm² 2.5 22 0 V Battery AKG 2AWG/35mm² 3.5 31

(-) Battery Terminal Screw M6 4 35 Signals Phoenix Mini Combicon 0.25 2 AC Input UK10 / UKLKG10 1.5-1.8 13-16 SPD Terminal Screw M5 4.5 40

TORQUE (Inch LB)

Table 6-1 Connection Torque Setting Check

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).

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Fault Possible Cause Suggestion/Solution Low System

Module failure.

Replace faulty module.

Voltage

Loss of AC power.

Verify AC input connection.

High System Voltage

Mains Error

AC Low V oltage

AC High Voltage

Module Failure

Load exceeds module capacity. Module failure.

System voltage exceeds the set limit.

Add module to system. Replace the faulty module.

Check the High Voltage Alarm limit setting.

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

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

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

Verify the AC Input voltage.

Faulty module.

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

Check if module sends alarm ag.

Verify the AC voltage to the failed module.

Urgent Module Failure

High Load

Overvoltage Shutdown

Manual No. aspiro2u-3

Rectier current sharing fault.

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.

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Fault Possible Cause Suggestion/Solution Load/Battery

Disconnection

System voltage drops below the set limit.

Check the battery condition. Check the AC mains connection.

System shutdown.

Check the input breaker.

Check the rectier modules.

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.

Distribution Fuse Failure

Tripped load breaker / blown load fuse.

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.

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.

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Fault Possible Cause Suggestion/Solution Battery Fuse

Failure

Tripped load breaker / blown load fuse

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.

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

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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: sales@unipowerco.com

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Chapter 7 Replacing Modules

7.1 Controller Replacement

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

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

Figure 7-1 Unlocking the Controller

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

Figure 7-2 Removing the Controller

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

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

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

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7.2 Rectier Replacement

NOTE Rectiers can be hot-swapped.

7.2.1 XR04.48 / XR08.48 Replacement

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

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

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

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

3. Replace the module and fasten the screw.

Release spring

Handle

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

7.2.2 XPGe12.48 Replacement

1. Insert a at screwdriver into the rectangular opening next to the left handle to unlock it, Figure 6-4 (1).

2. Once unlocked, pull both handles down and remove the rectier from the slot, Figure 6-4 (2).

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

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

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

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POWERING TECHNOLOGY

1 2

Figure 7-4 Replacing an XPGe12.48 Rectier

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. Unscrew the three retaining screws and then remove the front and the top covers see Figure 7-5 and Figure 7-6.

Manual No. aspiro2u-3

Figure 7-5 Removing the front panel

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Figure 7-6 Removing the top cover

2. Pull out the faulty breakers Figure 7-7.

Figure 7-7 Pulling out a faulty breaker

3. Install the correct breakers, front panel and the top cover.

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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.

3. Pull out the failed surge protection module.

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

5. Reinstall the top cover.

6. Switch on AC input power.

7.5 Other Requirements

Verify at least once a year if the output voltage is within acceptable limits. The result of the

test should be recorded and led to see any deviations.

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

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

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

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POWERING TECHNOLOGY

BATTERY

LOAD

Front View Layout Description

BREAKERS

Appendix A - Drawings

CONTROLLER

USB ETHERNET

F1 F2 F3 F4 F5 F6 F7 F8

FB2FB1

BREAKERS

XPGe12.48

10 10 101010101010

XPGe12.48

RECTIFIERS

XPGe12.48

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Installation Details - Connections

Battery string 2.

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

Battery type: 2 blocks

(-)24V

Battery string 1.

(-)24V

White White

Input mains terminals

1 2 3 4 5 6 7

3x400V AC

1 2 3 4 5 6 7

1x230V AC

PE1PE

1 2 3 4 5 6 7

3x230V AC

PE1PE

Symmetry cable connections

Battery symmetry 3

XC2

Battery symmetry 2

Battery symmetry 1

Battery string 2.

Battery string 1.

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

Temperature

sensor

Temperature

sensor

Alarm contacts

are shown in

alarm position

Battery type: 4 blocks

blue

(-)12V (-)24V

(-)36V

green red

blue green red

XC2

2 1

XC2

5 4

Alarm interface

XC2

2 1 6

XC2

5 4 3

XC3

2 1 6

XC3

5 4

XC4

- 1

XC4

- 4

3 2

XC5

1 6

XC5

4 3

XC6

1 6

XC6

4 4

XC7 2 1

4 3

XC8 2 1

Battery symmetry 3 Battery symmetry 2 Battery symmetry 1

Battery symmetry 6

Battery symmetry 5 Battery symmetry 4

Multi purpose 3 Multi purpose 2 Multi purpose 1

Multi purpose 6

Multi purpose 5 Multi purpose 4

Multi purpose 9 Multi purpose 8 Multi purpose 7

Multi purpose 12

Multi purpose 11 Multi purpose 10

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

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Block Diagram

-48V

RS485

Com.

J12

J11

-48V

RS485

Com.

J12

J11

Rectifier backplane - Top

Rect#3: XPGe12.48/

XR08.48/ XR04.48

Rectifier backplane -Bottom

Rect#1: XPGe12.48/

XR08.48/ XR04.48

Rect#4: XPGe12.48/

XR08.48/ XR04.48

Rect#2: XPGe12.48/

XR08.48/ XR04.48

Optional SPD

11 14

0V Battery

-48V

Optional

Connection

for PDU

Shunt

LVD

-/A1+/A2

0V Load

- Battery 1

- Battery 2

RS485

- Load 1

Breaker alarm for

XC4

Temp1

Temp2

+5V1

+5V2

GND

321

- Load n

- PLD Load 1

- PLD Load n

External Load

PDU

XC3

7-12

Multi purpose

321

Multi purpose

XC2

1-6

321

Optional PLD

-/A1+/A2

Batt breaker

Load breaker

MH1 MH2

Internal connections

Shunt Sense -

Shunt Sense +

Batt. Breaker

Load Breaker

LVD Disconnect

LVD Reconnect

Shunt Sense-

Shunt Sense+

Batt. Breaker

Load Breaker

PLD Disconnect

PLD Reconnect

1 0V 2 -48V

XC7

XC3

XC9A

XC9B

board

SPD alarm XC6

XC10

XC5 Door alarm

XC4

XC8

XC2

XC1

0V 1

-48V 2

1 2

RS232

CAN

System

voltage out

Dig Out 1

ACC / PCC

controller

XC1

XC8

XC7

+ Systemvoltage Out

- Systemvoltage Out

Dig Out 2

Dig In 1

Dig In 2

4321

B1-1 B2-1

L1-1 Ln-1

Ln-1 Ln-1

Fuse alarm board

External connections board

XC6 XC5

Alarm 1

Alarm 2

Alarm 3

Alarm 4

+5V Out

GND

NCC N

4321

NCC NONCC N

321

654

321

654

4/ 9

USB 2.0 / RS 232

Ethernet

GND

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3.0 (76.2)

Detailed Dimensions - Fixed Bracket Option

0.06 (1.6)

11.63 (295.4)

17.37 (441.2)

21.1 (535)

19.0 (482.6)

20.3 (515)

2.95 (75)

18.3 (465)

12.69 (322.2)

Note: ETSI mounting details are shown in green.

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3.0 (76.2)

Detailed Dimensions - Slide Bracket Option

0.06 (1.6)

11.63 (295.4)

17.65 (448.4)

20.3 (515)

21.1 (535)

1.25 (31.7)

19.0 (482.6)

18.3 (465)

2.95 (75)

0.98 (25)

12.69 (322.2)

Note: ETSI mounting details are shown in green.

Manual No. aspiro2u-3

Page 49

1.75 (44.5)

3.5 (88)

aspiro2u_m23-man-rev3-0516.indd

Unipower XPGe12.48, XR08.48, XR04.48 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Objectives

1.2 Audience

1.3 Document Key

1.4 Feedback & Support

1.6 Disclaimer

2.1 Overview

Figure 2-1 Power System Overview

2.2 System Parameters

2.3 System Components

2.3.1 System Controller

2.3.2 DC Distribution Unit

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

3.1 Safety Warnings and Guidelines

3.1.1 System Markings

3.1.2 Safety Recommendations

3.1.3 Installation Warning

3.1.4 Restricted Access Area Warnings

3.1.5 System Enclosure

3.1.6 Operating Temperature Warnings

3.1.7 Electrical Safety Warnings

3.1.8 Grounding

3.1.9 Batteries

3.1.9.1 Lead Acid Batteries

3.1.10 In Case of an Accident

3.2 Caution

3.2.1 Storage and Transportation

3.2.2 Disposal

3.2.3 Handling Electrostatic Sensitive Devices

3.2.4 Traceability

3.2.5 Breakers

3.2.6 Hot Surfaces

4.1 Unpacking

4.2 Tools

4.3 Rack Mounting

Figure 4-1 System Mounting

Figure 4-2 Slide Bracket Fixing

Figure 4-3 System Bracket Fixing

4.4 Cable Entry

Figure 4-4 System With Cover Removed

Figure 4-5 Grounding Connection

4.6 AC Input Connection

Figure 4-6 AC Input Terminal Block (1-phase)

Figure 4-7 AC Connection Options

4.7 DC Load Connection

Figure 4-8 DC Load Connection

4.8 Battery Connection

Figure 4-9 Battery Connection

4.9 Alarm and Signal Connections

Figure 4-10 Alarm Connections

4.10 Symmetry Connection

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

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

4.11 Temperature Sensor Connection

Figure 4-13 Temperature Sensor Connection

4.13 Connection of External PDU to DC Parallel Kit (Option)

Figure 4-15 External PDU Connection

Figure 4-16 DC Parallel Principle

4.14 Reinstalling Top Cover

5.1 Commissioning Overview

5.2 Tools and Test Equipment

5.2.1 Tools List

5.2.2 Test Equipment

5.3 Preparation

5.4 Commissioning procedure

5.5 Test of output voltage

5.5.1 Float charge (U1)

5.5.2 Adjustment of Float Charge, U1

5.5.3 Boost charging (U2) (if applicable)

5.6 Battery supervision

5.7 Battery test

5.8 Commissioning record

6.1 Maintenance

6.1.1 Checking Terminal Connection

6.2 Troubleshooting

7.1 Controller Replacement

Figure 7-1 Unlocking the Controller