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Unipower Aspiro 1U, XPGe12.48, XR08.48, XR04.48 Instruction Manual

POWERING TECHNOLOGY
Power Supply System
Aspiro 1U
Instruction Manual
Document Number: M00035-MAN rev. 3a
www.unipowerco.com
© 2017 UNIPOWER LLC
All Rights Reserved
UNIPOWER LLC • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • sales@unipowerco.com
POWERING TECHNOLOGY
Copyright © 1999-2017 UNIPOWER LLC
All Rights Reserved
Restricted Rights Legend:
Use, duplication, or disclosure by the Government is subject to restrictions as set forth in subparagraph © (1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS
252.227-7013 or subparagraphs © (1) and (2) of Commercial Computer Software - Restricted Rights at 48 CFR 52.227-19, as applicable.
For Contact Information, please go to http://www.unipowerco.com/contact/
Refer to the UNIPOWER License Agreement in this package before installing or using this product.
Unless specically noted, all addresses, data characters and persons referenced herein, and all examples involving names of companies and products, are ctitious examples and are designed
solely to illustrate the use of UNIPOWER products.
Product names, logos, brands, and other trademarks featured or referred to within this product manual are the property of their respective trademark holders. These trademark holders are not
aliated with UNIPOWER LLC or our products. They do not sponsor or endorse our products.
LIMITATIONS AND AUTHORIZATIONS FOR USE AND PERMITTED APPLICATIONS
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.
Document No. M00035-MAN rev. 3a
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POWERING TECHNOLOGY
Contents
Chapter 1 About This Manual
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
2.1 Overview ....................................................................................................................................8
2.2 System Congurations ...............................................................................................................8
2.3 System Parameters .....................................................................................................................9
2.4 System Components.................................................................................................................11
2.4.1 System Controller ...........................................................................................................11
2.4.2 DC Distribution ...............................................................................................................11
2.4.4 Rectier Module .............................................................................................................12
Chapter 3 System Safety
3.1 Safety Warnings and Guidelines ..............................................................................................13
3.1.1 System Markings ............................................................................................................13
3.1.2 Safety Recommendations ................................................................................................13
3.1.3 Installation Warning ........................................................................................................14
3.1.4 Restricted Access Area Warnings....................................................................................14
3.1.5 Electrical and Fire Enclosure ..........................................................................................14
3.1.6 System Enclosure ............................................................................................................14
3.1.7 Operating Temperature Warnings ...................................................................................14
3.1.8 Electrical Safety Warnings ..............................................................................................14
3.1.9 Grounding .......................................................................................................................15
3.1.10 Batteries ........................................................................................................................16
3.1.10.1 Lead Acid Batteries ........................................................................................16
3.1.11 In Case of an Accident ..................................................................................................16
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 ..........................................................................................................................17
3.2.5.1 Circuit Breaker Limitations .............................................................................17
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POWERING TECHNOLOGY
Chapter 4 Installation Guide
4.1 Introduction ..............................................................................................................................19
4.2 Unpacking ................................................................................................................................19
4.3 Tools 19
4.4 Rack Mounting .........................................................................................................................19
4.5 Rear Connections .....................................................................................................................21
4.5.1 DC Earth Connection (FRAME GROUND) ..................................................................21
4.5.2 Mains Connection ...........................................................................................................22
4.5.3 Alarm and Signal Connections ........................................................................................23
4.5.4 DC Load Connections .....................................................................................................25
4.5.5 Battery Connections .......................................................................................................26
4.5.6 Symmetry Connection ....................................................................................................27
4.5.7 Temperature Sensor Connection .....................................................................................28
Chapter 5 Commissioning
5.1 Commissioning Overview .......................................................................................................29
5.2 Tools and Test Equipment ........................................................................................................29
5.2.1 Tools List .........................................................................................................................29
5.2.2 Test Equipment ...............................................................................................................29
5.3 Preparation ...............................................................................................................................29
5.4 Commissioning procedure .......................................................................................................30
5.5 Test of output voltage ...............................................................................................................31
5.5.1 Float charge (U1) ............................................................................................................31
5.5.2 Adjustment of Float Charge, U1 .....................................................................................31
5.5.3 Boost charging (U2) (if applicable) ................................................................................31
5.6 Battery supervision ..................................................................................................................32
5.7 Battery test ...............................................................................................................................32
5.8 Commissioning record .............................................................................................................33
Chapter 6 Maintenance & Troubleshooting
6.1 Maintenance .............................................................................................................................34
6.2 Troubleshooting .......................................................................................................................34
Chapter 7 Replacing Modules
7.1 Controller Replacement ...........................................................................................................38
7.2 Rectier Replacement ..............................................................................................................39
7.2.1 XR04.48 / XR08.48 Replacement ..................................................................................39
7.2.2 XPGe12.48 Replacement ................................................................................................39
7.3 Breaker Replacement ...............................................................................................................40
Appendix A - Block Diagram ......................................................................................................42
Appendix B - CSA Certicate Extract .......................................................................................43
Appendix C - Revision History ...................................................................................................44
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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 Dimensional Drawing (Front and Top View) ..........................................................20
Figure 4-2 System Mounting (19” mount) ................................................................................20
Figure 4-3 Rear Connections .....................................................................................................21
Figure 4-4 DC Earth Connections .............................................................................................21
Figure 4-5 Mains Connection (viewed from rear) .....................................................................22
Figure 4-6 Mains Connection Detail .........................................................................................23
Figure 4-7 Signal Pin Designations ...........................................................................................24
Figure 4-8 Signal Connection Detail .........................................................................................25
Figure 4-9 Load and Battery Connections (Rear View) ............................................................25
Figure 4-10 Signal Connection Detail .........................................................................................26
Figure 4-11 2-block Symmetry Measurement (for illustration only) ..........................................27
Figure 4-12 4-Block Symmetry Measurement (for illustration only) .........................................27
Figure 4-13 Temperature Sensor Connection ..............................................................................28
Figure 7-1 Unlocking the Controller .........................................................................................38
Figure 7-2 Removing the Controller .........................................................................................38
Figure 7-3 Replacing an XR04.48 or XR08.48 Rectier ..........................................................39
Figure 7-3 Replacing an XPGe12.48 Rectier ..........................................................................40
Figure 7-5 Top Cover Removal .................................................................................................40
Figure 7-6 Breaker Removal - A ...............................................................................................41
Figure 7-7 Breaker Removal - B ...............................................................................................41
TABLES
Table 4-1 Recommended Mains Circuit Protection .................................................................22
Table 4-2 Cable Sizes ..............................................................................................................26
Table 4-3 Cable Sizes ..............................................................................................................27
Table 5-1 Float/Boost Charge Voltages ...................................................................................31
Table 5-2 Commissioning Record ...........................................................................................33
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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 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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POWERING TECHNOLOGY
Table 1-1 Abbreviations
Abbreviation Description
PCC Prime Controller Card
ACC Advance Controller Card
LVD Low Voltage Disconnection
PLD Partial Load Disconnection
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/ for details.
Alternatively, email: technical.support.repair@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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POWERING TECHNOLOGY
1
4
Chapter 2 Aspiro System Description

2.1 Overview

Aspiro DC power systems oer a range of solutions for diverse applications such as broadband
access, cable head ends, micro/pico BTS Cells, Enterprise, E911, and GSM-R.
The Aspiro shelf system utilizes ecient, dense, and reliable plug-in rectier modules
XR04.48, XR08.48 or XPGe12.48, with output power available at either 400W, 800W or
1200W per rectier, based upon a soft-switching approach. Features include wide input
operating range, wide operating temperature, full self-protection and three LEDs for
immediate rectier status indication.
The power system can be managed locally through messages and alarm displayed on the LCD screen of the system controller or remotely, using the PC-based PowCom™ software, or through a web browser with Ethernet connection.
2.2 System Congurations
Aspiro 1U system consists of:
1. System Controller ACC Extended
2. 4 x Load and 1 x Battery breakers including LVD
3. XR04.48 / XR08.48 / XPGe12.48 Rectiers (Maximum 2)
4. Rear Connections
3
2
Document No. M00035-MAN rev. 3a

Figure 2-1 Power System Overview

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POWERING TECHNOLOGY

2.3 System Parameters

OUTPUT
Power (max) 2400W @ >180VAC, 800W @ <180VAC
Output Current 52A max. @ 46VDC, 45A nominal (see appendix B)
15A (Low Power Shelf version with 20A shunt)
Voltage 46-57VDC
INPUT
Voltage 85-275VAC (Single-phase, 2 x Single-phase)
Frequency 50-60Hz
Input Current 16A (Single-phase), 8A (2 x Single-phase)
Power factor >0.98
DC DISTRIBUTION
Battery Breakers 1 x (AIRPAX, IER Series)
Ratings 40A, 50A, 65A
Load Breakers 4 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) - used for symmetry inputs
Analog Outputs 4 x potential free relays (C, NC, NO)
Digital Inputs 2 x, Logic 0: U<10VDC, Logic 1: U>12VDC
Digital Outputs 2 x, open collector type
Temperature measurement 2 x Temperature probe (Battery, Ambient)
CONNECTIONS
Battery connections Stripped cable, max.16mm2, spring type connector
AC connections Stripped cable with ferule, max. 2.5mm2, screw type connector
Load breaker connections Stripped cable with ferule, max. 4mm2, screw type connector
Alarm connections Stripped cable with ferule, max. 1.5mm2, screw type connector
* For load breaker derating limitations see chapter 3.2.5 Breakers on page 3-6.
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POWERING TECHNOLOGY
RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48
E󰀩ciency 95% typical @ I
nom 90% typical @ I
out
nom 88% typical @ I
out
out
nom
Input Current (max) <7.3A <10.5A <5.3A
Output Current (max)
22.4A 15.0A 7.5A
53.5V oat
Output Power 1200W @ >180VAC
800W 400W
750W @ 90-180VAC
Operating Temperature
55°C 65°C 65°C
(without derating)
Input Voltage
90-300VAC 85-300VAC
(Nominal 100-240VAC)
Output Voltage 46-57VDC
Load sharing < 5% of nominal current
Dimensions (WxHxD) 40.6 (1.6”) x 101.62(4”) x 228.5(9”) mm
Weight 1.1 kg
Cooling Fan-cooled, speed and alarm controlled, air ow direction rear to front
Protection Short circuit proof, automatic current limiting, selective shutdown of modules at
excessive output voltage.
Alarms High output voltage/ shutdown, Low voltage/ module failure
LED Indication Green: Power ON
Yellow: Current limit/ thermal protection Fan failure / Over temperature Pre-warning / thermal protection
Communication Failure (ashing)
Red: Module failure / high output voltage shutdown
Audible noise <55dBA according to ISO7779
MECHANICAL
Dimensions (WxHxD) 480 mm x 44.45 mm x 266 mm
Weight of the system
6.5 kg
(fully equipped)
Mounting Options 19”/ ETSI / Mid-mount
Cable Entry Rear Access
STANDARD COMPLIANCE / ENVIRONMENTAL
EMC and Immunity ETSI EN 300 386 V.1.5
EN 55022 EN 55024, EN 61000-4
Safety EN 60950-1
Operating Temperature -40°C to +75°C, derating over +47°C (see appendix B)
Storage Temperature -40°C to +85°C
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POWERING TECHNOLOGY

2.4 System Components

The Aspiro system is delivered with all components mounted according to the ordered
conguration. The main components are described below and in later chapters of the manual.
There are 2 versions of Aspiro shelf available depending on the value of battery current shunt used: 20 A or 80 A.
CAUTION Low Power Shelf version (20 A version) provides better resolution for battery current reading and it is suitable for low power applications with maximum battery charge current less than 5A.

2.4.1 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

2.4.2 DC Distribution

DC Distribution consists of maximum 1 battery and 4 load breakers available in a variety of sizes.
The distribution unit is designed for switching the battery and load on and o.
The battery and load breakers are supervised by measuring the voltage drop across each breaker. In the case of load breakers, those which are not connected to any load will not cause a breaker alarm even if they are left open.
A battery fuse alarm is generated after the battery voltage drops below a certain level, depending on the actual battery capacity and condition.
Low Voltage Disconnect (LVD)
The system is equipped with a low voltage battery disconnect which prevents the batteries from deep discharging, thus prolonging the battery life. The disconnect requires a detected mains failure at the supervision unit (controller).
If disconnection occurs, the batteries will not supply power to the load until they have been recharged to a set voltage level, which can be adjusted by the user.
If disconnection occurs, the batteries will be reconnected when the mains supply returns.
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POWERING TECHNOLOGY
2.4.4 Rectier Module
The Fan-Cooled XPGe12.48 (1200W), XR08.48 (800W) and XR04.48 (400W) rectiers
are modular power supplies designed for parallel operation and hot-plug installation in the Aspiro Power Systems.
Each rectier provides extremely reliable DC power in a very high density. The module
incorporates power monitoring through an internal microprocessor, giving up to the
second updates to the system controller and companion rectiers. This guarantees 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.
Document No. M00035-MAN rev. 3a

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 on the left side of top cover.

3.1.2 Safety Recommendations

Any device that uses electricity requires proper guidelines to ensure safety.
• The Power System should only be installed or serviced by a qualied personnel.
• Always keep tools away from walkways and aisles. Tools present a tripping hazard
in conned areas.
• Keep the system area clear and dust-free during and after the installation.
• Always know the location of emergency shut-o switches in case of an accident.
• Always wear appropriate eye protection and use appropriate tools for working with high voltage equipment.
• Do not perform any action that creates a potential hazard to other people in the system area.
• Never work alone in potentially hazardous conditions.
• Always check for possible hazards before beginning work.
• Remove watches, rings and jewelry that may present a hazard while working on the power system.
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POWERING TECHNOLOGY

3.1.3 Installation Warning

The following safety guidelines should be observed when transporting or moving the system:
• Before moving the Power System, read the system specications sheet to determine whether the install site meets all the size, environmental, and power requirements.
• The system and the equipment included, should only be moved and installed by
qualied personnel to prevent bodily injury or any other hazardous conditions.

3.1.4 Restricted Access Area Warnings

The Power System is designed for installation in locations with restricted access often secured by a locking mechanism. It can therefore be accessed only by a trained service person, who is fully aware of the restrictions applied to the location, or by an authority responsible for the location.

3.1.5 Electrical and Fire Enclosure

The unit is for building-in. A suitable Electrical and Fire enclosure shall be provided.

3.1.6 System Enclosure

Appropriate measures need to be taken to avoid intrusion of any unwanted objects or insects into conductive areas of the power system as there is a potential risk of system damage.
Disclaimer: UNIPOWER LLC assumes no liability or responsibility for system failures resulting from inappropriate enclosure around the system.

3.1.7 Operating Temperature Warnings

To prevent the Power System from overheating, an automatic shutdown mechanism has been installed. It is not recommended to continually operate the Power System in an area that exceeds the maximum recommended operating temperature.

3.1.8 Electrical Safety Warnings

The following are electrical safety recommendations for working near the Power System:
WARNING Observe low voltage safety precautions before attempting to work on the system when power is connected. Potentially lethal voltages are present within the system.
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