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Unipower Aspiro 1U Instruction Manual

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P O W E R I N G
T E C H N O L O G Y
Power Supply System
Aspiro 1U
Instruction Manual
www.unipowerco.com
© 2017 UNIPOWER LLC
Document Number: M00035-MAN rev. 3a
All Rights Reserved
UNIPOWER LLC • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • sales@unipowerco.com
North America: +1 954-346-2442 • Latin America: +1 954-905-1078 • Europe: +44 1903 768200

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  • Page 1 © 2017 UNIPOWER LLC Document Number: M00035-MAN rev. 3a All Rights Reserved UNIPOWER LLC • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • sales@unipowerco.com North America: +1 954-346-2442 • Latin America: +1 954-905-1078 • Europe: +44 1903 768200...
  • Page 2 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.

  • Page 3: Table Of Contents

    P O W E R I N G T E C H N O L O G Y 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 Configurations .......................8...
  • Page 4 P O W E R I N G T E C H N O L O G Y 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...
  • Page 5 P O W E R I N G T E C H N O L O G Y 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”...

  • Page 6: Chapter 1 About This Manual

    Chapter 1 About This Manual P O W E R I N G T E C H N O L O G Y 1. About This Manual This chapter contains an overview of the information that is presented in this Power System Manual.

  • Page 7: Feedback & Support

    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 modification of the instructions provided in this manual. Page 7 Document No.

  • Page 8: Chapter 2 Aspiro System Description

    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 Configurations Aspiro 1U system consists of: 1. System Controller ACC Extended 2. 4 x Load and 1 x Battery breakers including LVD 3.

  • Page 9: System Parameters

    P O W E R I N G T E C H N O L O G Y 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...
  • Page 10 P O W E R I N G T E C H N O L O G Y RECTIFIER MODEL XPGe12.48 XR08.48 XR04.48 Efficiency 95% typical @ I 90% typical @ I 88% typical @ I Input Current (max) <7.3A <10.5A <5.3A Output Current (max)

  • Page 11: System Components

    P O W E R I N G T E C H N O L O G Y 2.4 System Components The Aspiro system is delivered with all components mounted according to the ordered configuration. 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.

  • Page 12: Rectifier Module

    P O W E R I N G T E C H N O L O G Y 2.4.4 Rectifier Module The Fan-Cooled XPGe12.48 (1200W), XR08.48 (800W) and XR04.48 (400W) rectifiers are modular power supplies designed for parallel operation and hot-plug installation in the Aspiro Power Systems.

  • Page 13: Chapter 3 System Safety

    Chapter 3 System Safety P O W E R I N G T E C H N O L O G Y 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.

  • Page 14: Installation Warning

    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.

  • Page 15: Grounding

    P O W E R I N G T E C H N O L O G Y 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.

  • Page 16: Batteries

    P O W E R I N G T E C H N O L O G Y 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. 3.1.10 Batteries WARNING When installing or replacing batteries, there is risk of explosion if an incorrect battery type is used.

  • Page 17: Caution

    P O W E R I N G T E C H N O L O G Y 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.
  • Page 18 P O W E R I N G T E C H N O L O G Y 2. Limitations for ambient temperature up to 55°C, maximum system output current 45 Amps: Maximum load per circuit breakers rated:1 A, 4 A, 5 A, 7.5 A, 10 A, 15 A, 20 A and 25 A is 80% of their nominal rate.

  • Page 19: Chapter 4 Installation Guide

    Keep vent openings from blocking. 4.1 Introduction This chapter provides detailed instructions for installing the Aspiro 1U Power System. 4.2 Unpacking Check that the received equipment is in accordance with the packing list. Ensure that the cabinet and the equipment have not been damaged during transportation.

  • Page 20: Figure 4-1 Dimensional Drawing (Front And Top View)

    P O W E R I N G T E C H N O L O G Y 18.90 (480.1) [19”] 0.27 (6.8 ) 1.25 (31.75) 18.21 (462.6) [19”] 22.21 (564.2) [23”] 1.72 22.90 (581.7) [23”] (43.6) 16.81 (426.9) 19” 23”...

  • Page 21: Rear Connections

    P O W E R I N G T E C H N O L O G Y 4.5 Rear Connections All cable connections for the Aspiro system are available at the rear of the system, see Figure 4-3. CAUTION Use UL-listed wires with an insulation rating to at least 90°C. WARNING Before inserting the cable into the connector, remove as little insulation on the cable as possible, to prevent the stranded conductor to come loose and touch any other conductive parts.

  • Page 22: Mains Connection

    P O W E R I N G T E C H N O L O G Y 4.5.2 Mains Connection WARNING Ensure that mains input is turned off before connecting. The grounding must be connected to PE terminal as first. N DETAIL 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.

  • Page 23: Alarm And Signal Connections

    P O W E R I N G T E C H N O L O G Y To connect: 1. Remove sufficient insulation from the cables and insert stripped cables into the appropriate terminal. 2. Tighten the corresponding terminal screw with a flat screwdriver, see Figure 4-6.

  • Page 24: Figure 4-7 Signal Pin Designations

    P O W E R I N G T E C H N O L O G Y Battery Ambient Temp. Temp. 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 Alarm Condition Shown Figure 4-7 Signal Pin Designations Page 24...

  • Page 25: Dc Load Connections

    P O W E R I N G T E C H N O L O G Y To connect: 1. Release a connector from the terminal using a screwdriver and pull it out. 2. Remove sufficient insulation from the cables and insert stripped cables into the appropriate connector.

  • Page 26: Battery Connections

    P O W E R I N G T E C H N O L O G Y Load Breaker Size 7.5A Wire Size 1/18 1/18 1/18 1/18 1/18 2.5/14 2.5/14 4/12 4/12 /AWG] Table 4-2 Cable Sizes 4.5.5 Battery Connections WARNING Improper handling with batteries can be dangerous.

  • Page 27: Symmetry Connection

    P O W E R I N G T E C H N O L O G Y Battery Breaker Size Wire Size 10/6 10/6 16/4 /AWG] Table 4-3 Cable Sizes 4.5.6 Symmetry Connection 1. Attach the interblock connection plates between the batteries. 2.

  • Page 28: Temperature Sensor Connection

    P O W E R I N G T E C H N O L O G Y NOTE The interblock Connection Kit is not delivered with the system. NOTE Symmetry cable is normally pre-connected to the system, see Figure 4-7. 4.5.7 Temperature Sensor Connection Temperature Sensor Connection for supervising battery temperature is usually delivered pre- installed when used.

  • Page 29: Chapter 5 Commissioning

    Chapter 5 Commissioning P O W E R I N G T E C H N O L O G Y 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.

  • Page 30: Commissioning Procedure

    P O W E R I N G T E C H N O L O G Y 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 sufficient torque. 2.

  • Page 31: Test Of Output Voltage

    P O W E R I N G T E C H N O L O G Y 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.

  • Page 32: Battery Supervision

    Temperature 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).

  • Page 33: Commissioning Record

    P O W E R I N G T E C H N O L O G Y 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.

  • Page 34: Chapter 6 Maintenance & Troubleshooting

    If the first 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...
  • Page 35 P O W E R I N G T E C H N O L O G Y Fault Possible Cause Suggestion/Solution Mains Error AC supply OFF on one rectifier in the Verify that the AC input breaker is system with one plugged in rectifier. AC supply OFF on at least two Verify AC input connection.
  • Page 36 P O W E R I N G T E C H N O L O G Y Fault Possible Cause Suggestion/Solution Communication Module failure. Check the non-communicating Failure address Modules not installed in the correct position. If the rectifier address does not communicate re-install the module Broken or disconnected and wait for 5 minutes.
  • Page 37 P O W E R I N G T E C H N O L O G Y Fault Possible Cause Suggestion/Solution Symmetry Fault Battery at end of life. Verify the battery condition. Wrong symmetry cable connection. Verify the symmetry cable connection.

  • Page 38: Chapter 7 Replacing Modules

    Chapter 7 Replacing Modules P O W E R I N G T E C H N O L O G Y 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 flat screwdriver, see Figure 7-1.

  • Page 39: Rectifier Replacement

    P O W E R I N G T E C H N O L O G Y 7.2 Rectifier Replacement NOTE Rectifiers can be hot-swapped. 7.2.1 XR04.48 / XR08.48 Replacement To replace an XR04.48 or XR08.48 rectifier, follow the steps below: 1.

  • Page 40: Breaker Replacement

    P O W E R I N G T E C H N O L O G Y Figure 7-3 Replacing an XPGe12.48 Rectifier CAUTION After rectifier rebooting, check that the green LED is lit. 7.3 Breaker Replacement WARNING Make sure the system is switched OFF. To replace a faulty circuit breaker, follow the steps below: 1.

  • Page 41: Figure 7-6 Breaker Removal - A

    5. Plug the Faston connector to the breaker. 6. Re-attach the top cover. This document is believed to be correct at time of publication and UNIPOWER LLC accepts no responsibility for consequences from printing errors or inaccuracies. Specifications are subject to change without notice.

  • Page 42: Appendix A - Block Diagram

    Appendix A - Block Diagram P O W E R I N G T E C H N O L O G Y AC Input XPGe12.48/ XR08.48/ XR04.48 AC/DC Converter RS485 Com. Batt+ Batt- XPGe12.48/ XR08.48/ XR04.48 AC/DC Converter BB In + V sys.

  • Page 43: Appendix B - Csa Certificate Extract

    Appendix B - CSA Certificate Extract P O W E R I N G T E C H N O L O G Y ELECTRICAL RATING Input, AC Maximum Output, DC Input Type A (max) V (dc) Single Phase (High Power) 100 - 240 16-11 50 - 60...

  • Page 44: Appendix C - Revision History

    Appendix C - Revision History P O W E R I N G T E C H N O L O G Y Revision Page(s) Description Approval/Date Altered cover, Change of document number to reflect new system, this placed footer, 2 on front cover and in footer of all other pages.

This manual is also suitable for:

Xpge12.48Xr08.48Xr04.48

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