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Unipower X75 Series Installation & Operating Manual

Dc power power system mk3 controller
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INSTALLATION & OPERATING MANUAL
X75 SERIES
DC POWER POWER SYSTEM
Mk3 Controller
www.unipowerco.com
© 2015 UNIPOWER LLC
Manual No. X75mk3-11
x75-man-Rev11-0815.indd
All Rights Reserved
NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: +1 954-346-2442 • Fax: +1 954-340-7901 • sales-northamerica@unipoweco.com
EUROPE • Parkland Business Centre, Chartwell Road, Lancing BN15 8UE, ENGLAND • Tel: +44(0)1903 768200 • sales-europe@unipoweco.com

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  • Page 1 X75 SERIES DC POWER POWER SYSTEM Mk3 Controller www.unipowerco.com © 2015 UNIPOWER LLC Manual No. X75mk3-11 x75-man-Rev11-0815.indd All Rights Reserved NORTH AMERICA • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, USA • Tel: +1 954-346-2442 • Fax: +1 954-340-7901 • sales-northamerica@unipoweco.com...

  • Page 2: Table Of Contents

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Contents INTRODUCTION .......................4 FEATURES & OPTIONS ....................5 SAFETY WARNINGS......................6 WARRANTY (summary) ....................7 UNPACKING AND INSPECTION ..................7 GENERAL SPECIFICATIONS ...................8 PRINCIPAL OF OPERATION ..................10 FRONT PANEL DESCRIPTION ..................11 REAR PANEL DESCRIPTION ..................12 10.0...
  • Page 3 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL FIGURES Figure 1 - X75 Compact Integrated DC Power System ..............4 Figure 2 - Block Schematic ......................10 Figure 3a - Front View with Breakers (configuration A) ...............11 Figure 3b - Front View with GMT Fuses (configuration B) ............11 Figure 4 - Rear Views of Base and Expansion Units ..............12...

  • Page 4: Introduction

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL INTRODUCTION Gravitas X75 is an ultra-compact, integrated DC power system. The base system is a 1RU shelf holding up to three hot-swap rectifier modules. This system produces up to 1950 watts output at -54.4, +27.2 or +13.6VDC.

  • Page 5: Features & Options

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL FEATURES & OPTIONS Standard Features 1RU High Base System  1RU High Expander Shelf  Remote Control & Monitoring via TPC/IP Ethernet LAN  Fully Integrated System  Up to 72A at -54.4VDC ...

  • Page 6: Safety Warnings

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL SAFETY WARNINGS The X75 Compact DC Power System operates at voltages that could potentially be hazardous. Furthermore, inadvertent short circuiting of the system battery and/or rectifier by mis-connection or other error could be harmful. This product should be handled, tested and installed only by qualified technical persons who are trained in the use of power systems and are well aware of the hazards involved.

  • Page 7: Warranty (Summary)

    THE INSTRUCTIONS. WARRANTY (summary) X75 Series DC power systems are warranted for two (2) years from date of shipment against defects in material and workmanship. This warranty does not extend to products which have been opened, altered or repaired by persons other than persons authorized by...

  • Page 8: General Specifications

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL GENERAL SPECIFICATIONS Inputs Supply Voltage: 85-264VAC Single Phase Each rectifier position is supplied via an individual IEC60320 C14 Inlet Socket. A 3-phase supply may be connected provided that the voltage presented to each individual rectifier position does not exceed 264VAC.
  • Page 9 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 6.4 Safety The X75 system is compliant with UL60950-1, EN60950-1, CSA22.2-60950-1 and all other derivatives of the core IEC60950-1 standard 2nd Edition when installed correctly within a restricted access environment. The X75 system is CE marked to indicate conformance to the European Union’s Low Voltage and EMC Directives.

  • Page 10: Principal Of Operation

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL PRINCIPAL OF OPERATION NETWORK COMMUNICATIONS ALARMS & REMOTE ACCESS SENSORS CONTROLLER RECTIFIER BATTERY RECTIFIER RECTIFIER CONFIG. 5 x LOAD BREAKERS RECTIFIER BATTERY CURRENT CURRENT SHUNT SHUNT CONFIG. 10 x LOAD FUSES...

  • Page 11: Front Panel Description

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL FRONT PANEL DESCRIPTION LOAD BREAKERS MAJA MINA LOAD BREAKERS ACFA MAJA MINA ACFA Figure 3a - Front View with Breakers (configuration A) GMT FUSES MAJA MINA GMT FUSES ACFA 1......10 MAJA MINA ACFA 1......10 Figure 3b - Front View with GMT Fuses (configuration B) Figures 3a and 3b show the two system configurations as viewed from the front with breakers and fuses respectively.

  • Page 12: Rear Panel Description

    To the right and below the battery breaker there is a 9-way D sub connector marked RS232. This connector provides a ‘console’ only function to UNIPOWER service personnel and should not be connected to for any other purpose. x75-man-Rev11-0815.indd Manual No.
  • Page 13 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL In the center of the unit are three bus bar terminals. To the left side is the VB or BAT terminal. This is connected to the ‘hot’ 9.4.1 or ‘feed’ side of the battery.
  • Page 14 At the right hand side of the base unit and also the expansion shelf are three IEC60320 C14 inlets. These provide individual AC input feeds to each of the 3 rectifier slots. The X75 employs UNIPOWER Sigma Series rectifiers which operate from a Universal 85-264VAC 50-60Hz single phase supply. The system is designed so that various single and 3-phase supply connections can be made.

  • Page 15: Led Indicators

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 10.0 LED Indicators LOAD BREAKERS MAJA MINA ACFA Figure 5 - LED Indicators GMT FUSES During normal operation there will be one green LEDs displayed as shown in figure 5 above. MAJA MINA ACFA The LED indicators provide visual indication of both status and alarm conditions as described 1......10...

  • Page 16: Making Connections To The X75

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 11.0 MAKING CONNECTIONS TO THE X75 11.1 DC Load Connections The DC load distribution connections at the rear left of the unit are clearly marked as follows: 11.1.1 Circuit breaker option. For each load circuit there are two terminals marked V1, V2, V3, V4 and V5 respectively for the DC ‘feed’...

  • Page 17: Figure 7 - Battery Temp. Probe & Alarm Relay Connector Pin-Out

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 11.2 Alarm Relay and Battery Temperature Probe Connections – J4 Connection to the Form-C alarm relay outputs is made through a 15-way spring clamp terminal connector. There are a total of 4 relay outputs with Normally Open, Normally Closed and Common Contacts available for connection. The individual relays contact sets are fully isolated and may be floated from GROUND by up to 100V.

  • Page 18: Figure 8 - Ethernet Connector Pin-Out

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 11.3 Ethernet Connection – J3 The X75 is connected to a TCP/IP LAN (Local Area Network) or directly to a PC using connector J3. This is a standard RJ45 network connector allowing connection of any generally available Ethernet cable. Note that if the X75 is to be connected directly to a PC rather than a LAN then a cross-over Ethernet cable will be required.
  • Page 19 A link cable if supplied with the EX75 chassis. 11.6 USB Console This connector is reserved for UNIPOWER factory use. Manual No. x75mk3-11 x75-man-Rev11-0815.indd Page 19...

  • Page 20: Installation

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 12.0 INSTALLATION The X75 can be mounted in either 19” or 23” racks by using the supplied brackets. Mount it from the front of the rack using the correct offsets to align with existing rack-mounted equipment.
  • Page 21 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL One by one, turn each output circuit breaker to the ON position and/or insert a GMT fuse and measure the DC voltage across the corresponding output terminals. The voltage should again read approximately 54.4, 27.2, or 13.6 volts. After each output is measured, turn OFF that circuit breaker and/or remove the GMT fuse and turn ON and/or insert a fuse in the next one.
  • Page 22 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Note that until AC power is applied to the system the controller will not activate the LVD contactor. 12.6 System Turn-On Perform the following operations: Set the battery and all load circuit breakers to the OFF position.

  • Page 23: Using The Controller Web Browser Interface

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.0 USING THE CONTROLLER WEB BROWSER INTERFACE The web pages can be accessed using a browser. Type the IP address of the controller into the address bar to access the index page. Recommended browsers are Internet Explorer or Firefox.
  • Page 24 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Click the Add button and type in the IP address of the controller in the format ‘http://xxx.xxx.xxx.xxx’ (substitute the IP address set in the controller). A warning will appear indicating that this is a security risk. Press Continue to allow the site to be added.
  • Page 25 The menu items in the ‘navigation’ frame can be used at all times to jump between the various pages. Clicking on the UNIPOWER logo at the top will navigate directly to the UNIPOWER web site www.unipowerco.com.

  • Page 26: Figure 11 - Status Web Page (Typical)

    Figure 11 - Status WEB Page (typical) The following describes the function of the different parts of the applet with the exception of FACTORY SETTINGS which is reserved for UNIPOWER use. At the top is the site name. This can be changed in the installation applet.
  • Page 27 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL The next section shows the various system parameters. Rectifier current – The total current being delivered by all the rectifiers in the system. This is always a positive value. Load current – The total current being delivered to the system loads. This is always a positive value.

  • Page 28: Figure 12 - Rectifier Status Web Applet (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL The final section shows which alarms are active in the system. If no alarms are detected then the text will show ‘OK’. There are 51 different alarm conditions which can be displayed here. If the alarms are not set up (have no check boxes checked in the alarm matrix) then the alarm will be disabled and will not show up in this area.
  • Page 29 This may be desirable when a particular rectifier is to be removed from the system for maintenance, although all UNIPOWER rectifiers are Hot-Swap, or for some other reason. To inhibit a rectifier first select it as previously described and then click on INHIBIT.

  • Page 30: Figure 13 - Installation Web Applet - System Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.3 Installation The installation page contains several tabs which are described in detail below. 13.3.1 - System Settings Figure 13 - Installation WEB Applet - system tab (typical) The System Settings tab allows some basic reference information to be entered about the site.

  • Page 31: Figure 14 - Installation Web Applet - Float & Tc Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL To restore parameters that have been changed and not yet uploaded click on REFRESH. 13.3.2 - Float & TC Figure 14 - Installation WEB Applet - float & tc tab (typical) The Float & TC tab is used to set up the voltage and temperature compensation of...

  • Page 32: Figure 15 - Installation Web Applet - Battery Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Calculated Maximum Float Voltage. This is the maximum voltage that the system can adjust to given the temperature compensation slope, nominal float voltage and temperature compensation temperature limits. Calculated Minimum Float Voltage. This is the minimum voltage that the system can adjust to given the temperature compensation slope, nominal float voltage and temperature compensation temperature limits.

  • Page 33: Figure 16 - Installation Web Applet - Float & Tc Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Battery Capacity (Amp-Hours). This is the capacity of one battery string. Total Installed Capacity. This is simply the number of strings multiplied by the battery capacity. This figure is only for reference, it is not currently used for any active functions.

  • Page 34: Figure 17 - Installation Web Applet - Lvd Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Enable Scheduled Equalization checkbox. Some batteries require equalization to be applied periodically. Check this check box to enable this feature. Further parameters must be set up to use this feature correctly. Equalization Voltage. The voltage to which the rectifiers will be raised to achieve the boost/equalize function.
  • Page 35 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL The LVD tab is the set up and control for the system low voltage disconnect contactors. The controller can control up to two contactors, but in X75 only LVD 1 is installed.

  • Page 36: Figure 18 - Installation Web Applet - Digital I/P Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.3.7 - Digital I/P Figure 18 - Installation WEB Applet - digital i/p tab (typical) The Digital I/P tab allows the user to set up the functions of the 16 digital inputs. Each input may be given a name and can be configured to alarm on open or closed contact.

  • Page 37: Figure 20 - Installation Web Applet - Shunts Tab (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL The Rectifiers tab is used to set up the rectifier type to use with the system. There are currently three options: RPCP/M/RSG (I²C based communications) RRS/RPCG (I²C based communications) RBSR (PMBus™ based communications) Enable DC Voltage walk-in checkbox.

  • Page 38: Figure 21 - Battery Management Web Applet (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.4 Battery Management The Battery Management page is used to configure, run and review the results of battery testing. The testing performed verifies that the battery voltage holds up above a specified voltage for the duration of the test.
  • Page 39 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Retrieve Result and associated combo-box of result names. To retrieve a battery test result, select the file name in the combo-box. Note that the name has the date and time encoded in it in the format YYYYMMDDhhmm. To retrieve the selected result and display it on the graph press the retrieve result button.

  • Page 40: Figure 22 - Alarm Matrix Web Applet (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.5 Alarm Matrix When the Alarm Matrix menu item is selected the following two section page will be displayed. Figure 22 - Alarm Matrix WEB Applet (typical) The top section presents 5 tabs where limits relating to temperature, voltage, current and minimum number of rectifiers (Other Alarms tab) can be defined.

  • Page 41: Figure 23 - Alarm Matrix Web Applet - Matrix Options (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL To restore parameters that have been changed and not yet uploaded click on REFRESH. 13.5.1 - Matrix The below show the full extent of the alarm matrix. Down the left hand side are the different system ‘inputs’...
  • Page 42 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Cont. Under Temp – An under temperature condition internal to the controller. Over Voltage – The system voltage has exceeded the over voltage threshold. Low Voltage – The system voltage has fallen below the low voltage threshold.

  • Page 43: Figure 24 - Alarm Matrix Web Applet - Temperature Alarm Settings (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Outputs K1-8 – Dry contact relays with changeover contacts. X75 uses K1-4 only. MAJ LED – LED indicating a major alarm. This is the red LED on the front panel display. MIN LED – LED indicating a minor alarm. This is the yellow LED on the front panel display.

  • Page 44: Figure 25 - Alarm Matrix Web Applet - Voltage Alarm Settings (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL External Under Temperature – This alarm will be active when the external temperature falls below the activation temperature. It will not deactivate until the temperature rises above the cancellation temperature. Controller Over Temperature – This alarm will be active when the internal temperature exceeds the activation temperature.

  • Page 45: Figure 27 - Alarm Matrix Web Applet - Other Alarm Settings (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Load Over Current – This alarm will activate if the load current rises above this threshold. The alarm will be canceled when the current falls below the cancellation threshold. Battery Over Current – This alarm will activate if the magnitude of the battery current rises above this threshold.

  • Page 46: Figure 28 - Network Settings Web Applet (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.6 Network Settings Clicking on Network Settings loads to Controller Network Settings page. This page is used to setup the Ethernet and E-Mail communications settings. Figure 28 - Network Settings WEB Applet (typical) 13.6.1 - Ethernet settings The following settings set up the Ethernet interface.
  • Page 47 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Enable email – If enabled, the controller will send out alert emails. The email function needs to be configured in the email settings section of this applet. Additionally each alarm required to send an email must be configured to do so in the alarm matrix.

  • Page 48: Figure 29 - Alarm Log Web Applet (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.7 Alarm Log Figure 29 - Alarm Log WEB Applet (typical) The alarm log page shows details of historical alarms detected by the controller. The colored indicators denote the following alarm levels: Green – Alarm cleared Yellow –Minor alarm condition –...

  • Page 49: Figure 30 - Data Log Web Applet (Typical)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.8 Data Log Figure 30 - Data Log WEB Applet (typical) The controller normally logs data once every 5 minutes (default). It logs the following parameters: • Voltage • Rectifier Current • Load Current • Battery Current • Battery Temperature 1 •...
  • Page 50 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL administrator password is necessary for this change. The label on the top right will update to show how long the log will run before beginning to overwrite the earliest entry. To display stored data, choose the start date/time of the period of interest using the date spinner box (upper left in the graph control section).
  • Page 51 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Parameter Size Format Range (bytes) Time stamp Long integer Milliseconds since midnight, 1st Jan 1970 Voltage Short integer -327.68V to +327.68V stored as 1/100ths of a volt Rectifier Current Short integer -32768A to +32768A (Systems will...

  • Page 52: Figure 31 - Change Password Web Applet

    13.9 Change Password The three password levels are FACTORY, ADMIN and USER. FACTORY is reserved for UNIPOWER use. USER provides access certain parameter updates while ADMIN provides access to all parameter updates with the exception of those related to factory setup.

  • Page 53: Figure 32 - Help Web Page

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL 13.10 Help & About Clicking on Help will display a link to the controller manual on the UNIPOWER web site. Figure 32 - Help WEB Page Clicking on About will display various inventory information, total and free RAM and flash memory and the time the system has been powered up since the last boot.

  • Page 54: Appendix 1 - Snmpv3 Mib Information

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Appendix 1 – SNMPv3 MIB Information The SNMP feature provides status read-out and alarm trapping only. All parameters described in this appendix are therefore read-only. Parameters for X75 Remote Access Controller MIB are organized into groups and are briefly described as follows.
  • Page 55 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Parameter Name Function rectifierOCA Rectifier over current alarm. (0) CLEAR, (1) OTHER, (2) MINOR, (3) MAJOR. loadOCA Load over current alarm. (0) CLEAR, (1) OTHER, (2) MINOR, (3) MAJOR. batteryOCA Battery over current alarm.
  • Page 56 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Measurement Groups - Voltage, Current, Temperature Parameter Name Function busVoltage Live bus voltage. rectifierCurrent Live rectifier current. loadCurrent Live load current. batteryCurrent Live battery current. batteryTemperaturex Live battery temperature. [1 only in X75]...
  • Page 57 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Parameter Name Function equalizeCurrentLimit Current above which equalization/boosting will be terminated. equalizeEnabled Equalize status. ENABLED (1) or DISABLED (0) equalizeAfterChargeEnabled Equalize extension after bulk charge status. ENABLED (1) or DISABLED (0) periodicEqualizeEnabled Periodic automatic equalization status.
  • Page 58 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Parameter Name Function externalUTAOn Temperature at which External Under Temperature Alarm activates. externalUTAOff Temperature at which External Under Temperature Alarm clears. controllerOTAOn Temperature at which Controller Over Temperature Alarm activates. controllerOTAOff Temperature at which Controller Over Temperature Alarm clears.
  • Page 59 Writing a 1 to this register will reboot the controller. mibCompliance Compliance statement for the UNIPOWER Controller 2 agent that implements this enterprise MIB module. mibGroup Objects in this enterprise MIB module for the UNIPOWER Controller 2. Traps Parameter Name Function batteryOTATrapOn One of the battery temperatures has exceeded the battery over temperature ON threshold.
  • Page 60 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Parameter Name Function externalUTATrapOff The external temperature has exceeded the external under temperature OFF threshold. controllerOTATrapOn The controller internal temperature has exceeded the controller over temperature ON threshold. controllerOTATrapOff The controller internal temperature has fallen below the controller over temperature OFF threshold.
  • Page 61 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Parameter Name Function digitalxTrapOn Digital Input is in an alarm state. [1 only in X75] digitalxTrapOff Digital Input alarm has cleared. [1 only in X75] nRectTrapOn There are insufficient rectifiers in the system.
  • Page 62 X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Configuring a trap destination in the controller using the iReasoning MIBBrowser. In the SNMP tree on the left, go to snmpV2>snmpTargetMIB>snmpTargetAddrTable. Right click this entry and choose table view. Use Create Row to create a new entry. Up to 4 entries are allowed.

  • Page 63: Appendix 2 - Load Lvd (Special Order)

    X75 SERIES - Mk3 Controller INSTALLATION & OPERATING MANUAL Appendix 2 – Load LVD (special order) This appendix replaces section 7 on page 10 of this manual NETWORK COMMUNICATIONS ALARMS & REMOTE ACCESS SENSORS CONTROLLER RECTIFIER BATTERY BATTERY CURRENT RECTIFIER SHUNT SPARE SLOT 2.5A LOAD BREAKERS RECTIFIER CURRENT SHUNT RETURN A 85-264VAC is supplied directly to each of the rectifiers which produce a nominal +12VDC output.

  • Page 64: Appendix 3 - Revision History

    Detail Page 08/15 First Release Mk3 version 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. x75-man-Rev11-0815.indd Manual No. x75mk3-11...

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