Unipower XPGe12.48, XR08.48, XR04.48 Instruction Manual
POWERING TECHNOLOGY
Power Supply System
Aspiro 2U Front Access
Instruction Manual
Document Number: ASPIRO2U-3
aspiro2u_m23-man-rev3-0516.indd
www.unipowerco.com
© 2016 UNIPOWER LLC
All Rights Reserved
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
Copyright © 1999-2016 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
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Rights at 48 CFR 52.227-19, as applicable.
For Contact Information, please go to http://www.unipowerco.com/contact/
Refer to the UNIPOWER License Agreement in this package before installing or using this product.
Unless specically noted, all addresses, data characters and persons referenced herein, and all
examples involving names of companies and products, are ctitious examples and are designed
solely to illustrate the use of UNIPOWER products.
Product names, logos, brands, and other trademarks featured or referred to within this product
manual are the property of their respective trademark holders. These trademark holders are not
aliated with UNIPOWER LLC or our products. They do not sponsor or endorse our products.
LIMIT ATIONS AND AUTHORIZA TIONS FOR USE AND PERMITTED APPLICA TIONS
UNIPOWER’s products are not designed, intended for use in, or authorized for use as critical
components in, human life support systems/equipment, equipment used in hazardous environments,
or equipment used in nuclear control equipment or systems. Any such use requires the prior
express written consent of an authorized executive ocer of UNIPOWER LLC, which consent
may be withheld by UNIPOWER LLC in its sole discretion. Users assume all risk and liability for,
and agree to indemnify and defend UNIPOWER from and against any claims for personal injury
(including death) or property damage resulting from any such use or application which is made in
the absence of such prior express written consent.
If you nd errors or problems with this documentation, please notify UNIPOWER. UNIPOWER
does not guarantee that this document is error-free. The information in this document is subject to
change without notice.
September 2015
Manual No. aspiro2u-3
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POWERING TECHNOLOGY
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 Rectier 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 Rectier 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 Rectier 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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POWERING TECHNOLOGY
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 Rectier 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 Rectier ...........................................................41
Figure 7-4 Replacing an XPGe12.48 Rectier ...........................................................................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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POWERING TECHNOLOGY
Chapter 1 About This Manual
1. About This Manual
This chapter contains an overview of the information that is presented in this Power System
Manual. This includes information on objectives, the intended audience, and the organization
of this manual. In addition, this chapter also denes the conventions used to indicate warnings,
cautions and noteworthy information.
1.1 Objectives
This manual describes the Power System, explains how to unpack and install the system,
how to perform the initial power-up and operational system check.
The information presented in this document is current as of the publication date.
1.2 Audience
This manual is to be used by installers and technicians who are preparing the site for a new
installation and installing the power system. This manual assumes that the technician has an
understanding of power systems in general and understands safety procedures for working
around AC and DC voltage.
The user of this document should be familiar with electronic circuitry and wiring practices
and have some expertise as an electronic, power, or electromechanical technician.
1.3 Document Key
This manual uses the following conventions:
WARNING This symbol indicates a situation that could cause bodily injury .
Always be aware of hazardous conditions when working in or around the
power system.
CAUTION This symbol indicates a situation that might result in equipment
damage. The reader should be aware that their actions could result in
equipment or data loss.
NEED MORE INFORMATION? This symbol is used to reference
information either in this manual or in another document.
NOTE This symbol means the reader should take note. Notes are helpful
suggestions or reminders.
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POWERING TECHNOLOGY
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 Rectier
XR08.48 800 W Rectier
XPGe12.48 1200 W Rectier
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
modication of the instructions provided in this manual.
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POWERING TECHNOLOGY
3
2
1
Chapter 2 Aspiro System Description
2.1 Overview
Aspiro DC power systems oer a range of solutions for diverse applications such as broadband
access, cable head ends, micro/pico BTS Cells, Enterprise, E911, and GSM-R.
The Aspiro shelf system utilizes ecient, dense, and reliable plug-in rectier modules
XR04.48, XR08.48 or XPGe12.48, with output power available at either 400W, 800W or
1200W per rectier, based upon a soft-switching approach. Features include wide input
operating range, wide operating temperature, full self-protection and three LEDs for
immediate rectier status indication.
The Power system is highly congurable 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
6
5. Internal Connection Board
6. AC Surge Protection Device (Option)
7. Rectier Module
8. Battery Distribution Unit
4
8
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Figure 2-1 Power System Overview
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POWERING TECHNOLOGY
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
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
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POWERING TECHNOLOGY
RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48
Eciency 95% typical @ I
nom 90% typical @ I
out
nom 88% typical @ I
out
out
nom
Input Current (max) <7.3A <10.5A <5.3A
Output Current (max)
22.4A 15.0A 7.5A
53.5V oat
Output Power 1200W @ >180VAC
800W 400W
750W @ 90-180VAC
Operating Temperature
55°C 65°C 65°C
(without derating)
Input Voltage
90-300VAC 85-300VAC
(Nominal 100-240VAC)
Output Voltage 46-57VDC
Load sharing < 5% of nominal current
Dimensions (WxHxD) 40.6 (1.6”) x 101.62(4”) x 228.5(9”) mm
Weight 1.1 kg
Cooling Fan-cooled, speed and alarm controlled, air ow direction rear to front
Protection Short circuit proof, automatic current limiting, selective shutdown of modules
at excessive output voltage.
Alarms High output voltage/ shutdown, Low voltage/ module failure
LED Indication
Green: Power ON
Yellow: Current limit/ thermal protection
Fan failure / Over temperature
Pre-warning / thermal protection
Communication Failure (ashing)
Red: Module failure / high output voltage shutdown
Audible noise <55dBA according to ISO7779
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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POWERING TECHNOLOGY
2.3 System Components
The Aspiro system is delivered with all components mounted according to the ordered
conguration. The main components are described below and in later chapters of the manual.
2.3.1 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 congured 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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POWERING TECHNOLOGY
2.3.3 Rectier Module
The Fan-Cooled XPGe12.48 (1200W), XR08.48 (800W) and XR04.48 (400W) rectiers
are modular power supplies designed for parallel operation and hot-plug installation in
the Aspiro Power Systems.
Each rectier provides extremely reliable DC power in a very high density. The module
incorporates power monitoring through an internal microprocessor, giving up to the
second updates to the system controller and companion rectiers. This guarantees
tightly controlled load sharing among rectiers, and provides status and identication
information to the controller.
The rectiers operate in parallel using active load sharing. They incorporate soft-start
at both the input and the output, which protects against high incoming and outgoing
currents. The output voltage of the rectier is automatically adjusted to the required
voltage by the controller.
XPGe12.48 rectiers cannot be used in the same rack as XR04.48 / XR08.48 rectiers.
CAUTION XPGe12.48 rectiers cannot be used in the same system as XR04.48/
XR08.48 rectiers.
Manual No. aspiro2u-3
Figure 2-2 XPGe12.48 and XR04.48/XR08.48
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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 qualied personnel.
• Always keep tools away from walkways and aisles. Tools present a tripping hazard
in conned 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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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 specications sheet to determine
whether the install site meets all the size, environmental, and power requirements.
• The system should only be moved by qualied 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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POWERING TECHNOLOGY
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 specications 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 specications of the system. In
addition, equipment connected to the system should not overload the circuit breakers
as this may have a negative eect on overcurrent protection and supply wiring, causing
system or user harm.
• Verify the DC capacity before making connections. See system specications 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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