Power Supply System Guardian Access 3U Instruction Manual

P O W E R I N G T E C H N O L O G Y
Power Supply System

Guardian Access 3U
Instruction Manual
Document Number: MS0027-MAN rev. 5 © 2019 UNIPOWER LLC

All Rights Reserved
UNIPOWER, LLC
65 Industrial Park Rd
Dunlap, TN 37327
Phone: +1-954-346-2442
Toll Free: 1-800-440-3504
Web site: www.unipowerco.com
Copyright © 1999-2019 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 https://www.unipowerco.com/contact/
Refer to the UNIPOWER License Agreement in this package before installing or using this product.
Unless specifically noted, all addresses, data characters and persons referenced herein, and all
examples involving names of companies and products, are fictitious 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
affiliated 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 officer 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 find 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.
REV DESCRIPTION CHK’d & APPR’d / DATE

5 PCO# 45397 MM / 07-31-19
Manual No. MS0027-MAN rev. 5 Page 2 guardian_access_3u_ms27-man-rev5-0719.indd

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
1.5 Disclaimer...................................................................................................................................7
Chapter 2 System Description.......................................................................................................8
2.1 Overview.....................................................................................................................................8
2.2 System Parameters....................................................................................................................11
2.3 System Components.................................................................................................................13
2.3.1 System Controller............................................................................................................13
2.3.2 DC Distribution Unit.......................................................................................................13
2.3.3 Rectifier Module..............................................................................................................14
Chapter 3 System Safety..............................................................................................................15
3.1 Safety Warnings and Guidelines...............................................................................................15
3.1.1 System Markings.............................................................................................................15
3.1.2 Safety Recommendations.................................................................................................15
3.1.3 Installation Warning.........................................................................................................16
3.1.4 Restricted Access Area Warnings....................................................................................16
3.1.5 System Enclosure.............................................................................................................16
3.1.6 Operating Temperature Warnings....................................................................................16
3.1.7 Electrical Safety Warnings...............................................................................................17
3.1.8 Grounding........................................................................................................................18
3.1.9 Batteries...........................................................................................................................18
3.1.9.1 Lead Acid Batteries..............................................................................................18
3.1.10 In Case of an Accident...................................................................................................19
3.2 Caution......................................................................................................................................19
3.2.1 Storage and Transportation..............................................................................................19
3.2.2 Disposal...........................................................................................................................19
3.2.3 Handling Electrostatic Sensitive Devices........................................................................19
3.2.4 Traceability......................................................................................................................19
3.2.5 Breakers...........................................................................................................................20
3.2.6 Hot Surfaces.....................................................................................................................20
Chapter 4 Installation Guide.......................................................................................................21
4.1 Preparation................................................................................................................................21
4.1.1 Installation Overview.......................................................................................................21
4.1.2 Unpacking........................................................................................................................21
4.1.3 Tools.................................................................................................................................22
4.1.4 Cable Size........................................................................................................................23
4.2 Rack Mounting..........................................................................................................................24

4.3 Cable Entry...............................................................................................................................26

4.3.1 Remove Top Cover..........................................................................................................26
4.3.2 Cable Entry Openings......................................................................................................27
4.5 AC Input Connection................................................................................................................29
4.6 DC Load Connection................................................................................................................31
4.7 Battery Connection...................................................................................................................32
4.8 Alarm and Signal Connections..................................................................................................32
4.9 Symmetry Connection..............................................................................................................35
4.10 Temperature Sensor Connection.............................................................................................36
4.11 Connecting an RS232 Communication Cable........................................................................37
4.12 Rectifier Installation................................................................................................................37
4.13 Reinstalling Top Cover...........................................................................................................38
Chapter 5 Commissioning............................................................................................................39
5.1 Commissioning Overview........................................................................................................39
5.2 Tools and Test Equipment.........................................................................................................39
5.2.1 Tools List..........................................................................................................................39
5.2.2 Test Equipment................................................................................................................39
5.3 Preparation................................................................................................................................39
5.4 Commissioning procedure........................................................................................................40
5.5 Test of output voltage................................................................................................................41
5.5.1 Float charge (U1).............................................................................................................41
5.5.2 Adjustment of Float Charge, U1......................................................................................41
5.5.3 Boost charging (U2) (if applicable).................................................................................41
5.6 Battery supervision...................................................................................................................42
5.7 Battery test................................................................................................................................42
5.8 Commissioning record..............................................................................................................43
Chapter 6 Maintenance & Troubleshooting...............................................................................44
6.1 Maintenance..............................................................................................................................44
6.1.1 Checking Terminal Connection.......................................................................................44
6.1.2 Other Requirements.........................................................................................................44
6.2 Troubleshooting........................................................................................................................45
Chapter 7 Replacing Modules......................................................................................................49
7.1 Controller Replacement............................................................................................................49
7.2 Rectifier Replacement...............................................................................................................49
7.3 Battery and Load Breakers Replacement..................................................................................50
7.4 Surge Protection Device Replacement......................................................................................50
Appendix A - Drawings.................................................................................................................51
A.1 System Layout..........................................................................................................................51
A.2 Installation Details - Connections............................................................................................52
A.3 Block Diagram.........................................................................................................................53
A.4 Detailed Dimensions................................................................................................................54

FIGURES
Figure 2-1 Power System Overview..............................................................................................8
Figure 2-2 Principal of Operation..................................................................................................9
Figure 2-3 Power System With Extension Rear and Top Cover Kit...........................................10
Figure 2-4 Power System with Rear and Top Cover Kit.............................................................10
Figure 2-5 Guardian Rectifier......................................................................................................14
Figure 4-1 System Mounting - Cabinet.......................................................................................24
Figure 4-2 System Mounting - Open frame / relay rack..............................................................25
Figure 4-3 Remove Top Cover....................................................................................................26
Figure 4-4 Remove Top and AC Input Cover..............................................................................27
Figure 4-5 Cable Entry Options...................................................................................................27
Figure 4-6 Grounding Connection...............................................................................................28
Figure 4-7 Grounding Connection with Extended Rear Cover - Two Point...............................28
Figure 4-8 Grounding Connection with Extended Rear Cover - Single Point............................29
Figure 4-9 AC Input Terminal Block (1-phase)...........................................................................30
Figure 4-10 AC Input Terminal Block (3-phase)...........................................................................30
Figure 4-11 DC Load Connection.................................................................................................31
Figure 4-12 Battery Connection....................................................................................................32
Figure 4-13 PCC External Board...................................................................................................33
Figure 4-14 ACX External Board..................................................................................................33
Figure 4-15 ACX Relay Board......................................................................................................34
Figure 4-16 2-block Symmetry Measurement (for illustration only)............................................35
Figure 4-17 4-Block Symmetry Measurement (for illustration only)...........................................35
Figure 4-18 Temperature Sensor Connection................................................................................36
Figure 4-19 RS232 Connection.....................................................................................................37
Figure 4-20 Rectifier Installation...................................................................................................38
Figure 7-1 Unlocking and Removing the Controller...................................................................49
Figure 7-2 Replacing a Surge Protection Module.......................................................................50
TABLES
Table 4-1 Recommended Electrical Cable Size.........................................................................23
Table 5-1 Float/Boost Charge Voltages......................................................................................41
Table 5-2 Commissioning Record..............................................................................................43
Table 6-1 Connection Torque Setting Check.............................................................................44

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 defines 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.

Table 1-1 Abbreviations

Abbreviation Description
ACX Advance Controller Card
FMD Fan-cooled Modular Power Converter
FMP Fan-cooled Modular Power Rectifier
GDN Guardian system
LVD Low voltage disconnection
MCB Miniature circuit breaker
PCC Prime Controller Card
PLD Partial load disconnection
SLI SLI Inverter
1.4 Product Support

Product support can be obtained using the following addresses and telephone numbers.
Corporate office: Manufacturing facility: Manufacturing facility:

UNIPOWER, LLC UNIPOWER, LLC UNIPOWER Slovakia SRO
210 N University Dr 65 Industrial Park Rd ZLATOVSKA 1279
Coral Springs, FL 33071 Dunlap, TN 37327 Business Center 22
United States United States 91105 Trencin, Slovakia
Phone: +1-954-346-2442
Toll Free: 1-800-440-3504
Web site – www.unipowerco.com
When contacting UNIPOWER, please be prepared to provide:
1. The product model number, spec number, S build number, and serial number
- see the equipment nameplate on the front panel
2. Your company’s name and address
3. Your name and title
4. The reason for the contact
5. If there is a problem with product operation:
• Is the problem intermittent or continuous?
• What revision is the firmware?
• What actions were being performed prior to the appearance of the problem?
• What actions have been taken since the problem occurred?
1.5 Disclaimer
UNIPOWER is not responsible for system problems that are the result of installation or
modification of the instructions provided in this manual.

Chapter 2 System Description
2.1 Overview
This chapter contains an overview of the system and a short description of the units in the
system.
The Guardian Access 3U power system is designed to meet the requirements of modern
telecommunications equipment. This power solution provides rectification, system
management and power distribution. The power system is based the Guardian family of
on fan-cooled, hot-swappable rectifier modules FMPe20.48G, FMP25.48 or FMPe30.48G;
each with an output of up to 2000W, 2500W or 2900W respectively. Two additional modules
FMP20.48 and FMPe30.48C at 2000W and 2900W are also available in the Asia / Pacific
region.
The power system can be managed locally through messages and alarms displayed on the
LCD screen of system controller, or remotely using the PC-based PowCom™ software
package.
The power system contains 3 or 5 rectifier positions and modules depending on your order,
one system controller, and distribution unit.
The Guardian Access 3U system consists of:
1. System Controller 5. Alarm Interface Board
2. Internal Connection Board 6. AC Surge Protection Device (Option)
3. Rectifier Module 7. AC Input Terminal Block
4. Load and Battery Distribution
6
7 5
1 3
Figure 2-1 Power System Overview
NOTE If you order a power system with 3 rectifier positions, the bottom two slots will be
unavailable and should be left blank.

The Guardian Access 3U is capable of delivering up to 14.7kW steady state power to the
combined load and batteries. The maximum power available to the load is 10.7kW. The
system is based on hot-swappable 48V rectifier modules which are working in parallel with
automatic load sharing.
The power system is normally configured with N+1 redundancy, with N as the number
of rectifier modules necessary for feeding the load and charging the battery and 1 as the
redundant rectifier module. In normal operation the rectifier modules are used to feed the
load and simultaneously maintain the batteries in a fully charged state.
Once the mains input power is failed, the rectifiers are shut down and the batteries feed
the load immediately. If the battery voltage drops below a preset level, the Low Voltage
Disconnection (LVD) circuit disconnects the batteries automatically to prevent over-discharge
of the battery to prolong battery life. When the mains input power is restored, the rectifiers
will start up automatically to feed the load, close LVD circuit and recharge the batteries.
System performance is supervised and controlled by the controller, PCC or ACX Advanced.
The DC output voltage, alarm thresholds, LVD circuit operation, temperature compensated
battery charging can be set by the controller. Any malfunction will be indicated by LED, text
in the display and operation of dry contacts.
However, the system controller is not a single point of failure. In the event of controller
malfunction, basic tasks like feeding the load and charging batteries will be maintained by
the rectifier modules directly at preset default values.
The alarm and threshold setting of the power system can be set either through the buttons
and operation menu on the local controller, or remotely through the PowCom™ supervision
software.
Controller
DC Distribution
Rectifier
AC Load Breakers
Rectifier
LVBD
Battery Breaker
Battery
Figure 2-2 Principal of Operation

To meet the requirements of different application, there are two kinds of Rear and Top Cover
Kit available:
• Rear and Top Cover Kit for cabinets
• Extension Rear and Top Cover Kit for open relay racks.
DC & Alarm
Cable Entry
AC Cable Entry
Figure 2-3 Power System With Extension Rear and Top Cover Kit
NOTE The cable entry on the rear of the shelf is factory supplied and opened. If you want
to route the cables from the bottom or side, remove the knockouts. For AC cable entry, you
have to install the supplied PG21.
DC & Alarm
Cable Entry
AC Cable Entry
Figure 2-4 Power System with Rear and Top Cover Kit
NOTE The Rear and Top Cover Kit and Extension Rear and Top Cover Kit are optional
components and just provided according to your order.

2.2 System Parameters
OUTPUT
Power (max) 10.7kW load + 4kW battery charge @ 230/400VAC nominal
9.4kW load + 4kW battery charge @ 120VAC nominal
Output Current (max) 200A load + 75A battery charge @ 230/400VAC nominal
175A load + 75A battery charge @ 120VAC nominal
Voltage 44-57.6VDC
INPUT
Voltage Range 100-120VAC, 1W+N+PE, 50/60Hz
200-240VAC, 2W+PE, 50/60Hz
208-240/360-416VAC, 3W+N+PE, 50/60Hz
Frequency 47-63Hz
Input Current 1-phase 82A @ 100-120VAC, 65A @ 200-240VAC
3-phase 25A per phase @ 230/400VAC
Power factor >0.98
Surge Protection Optional
DC DISTRIBUTION & BATTERY MANAGEMENT
Battery Breakers 1, 2 or 3 x 80A, 100A or 125A
Symmetry Inputs Up to 6
Programmable LVD / PLD 125A or 200A (voltage) / 125A or 200A (voltage/time)
Load Breakers 9 x 18mm / 13 x 13mm, depending on number of battery breakers.
Ratings single pole - 4A, 6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, 63A
(see datasheet for details) two pole - 80A, 100A; three pole - 125A, 150A
MONITORING AND CONTROL
Controller PCC or ACX Advanced
Local Interface 4 x 20’ LCD, 4-key menu, USB (ACX 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 (ACX only)
Digital Outputs 2 x, open collector type (ACX only)
Temperature measurement 2 x Temperature probe (Battery, Ambient)
CONNECTIONS
Battery connections M8 lugs, +Ve common from bus bar
AC connections Max. 7AWG/10mm2, 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

MECHANICAL
Dimensions (WxHxD) 19” (483mm) x 5.2” (133mm) x 16.1” (408mm) std cover | 19.1”
(485)mm ext. cover
Weight of the system 67lbs (30.5kg)
(fully equipped)
Mounting Options 19”/ Mid-mount
Cable Entry Rear Access (top/rear covers have to be removed to make
connections)
STANDARD COMPLIANCE / ENVIRONMENTAL
EMC and Immunity EN 300 386 ; EN61000-6-3 (Emission) ; EN61000-6-2 (Immunity)
Safety IEC60950-1:2005 2 Ed. +A1:2009
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
RECTIFIER MODEL FMPe20.48G FMP25.48G FMPe30.48G

Efficiency 96% 92.5% 95%
Input Current (max) <11.6A <16.8A <17.0A
Output Current 37.4A 46.7A 54.2A
(53.5V float)
Output Power 1100W @ >180VAC 1400W @ >180VAC 1700W @ >180VAC
2000W @ 90-180VAC 2500W @ 90-180VAC 2900W @ 90-180VAC
Operating Temperature 55°C 55°C 55°C
(without derating)
Input Voltage 90-300VAC 85-300VAC
(Nominal 100-240VAC)
Output Voltage 44-57.6VDC
Load sharing < 5% of nominal current
Dimensions (HxWxD) 1.6 (41) x 4.2 (107) x 14 (355) ”(mm)
Weight 4.6lbs / 2.1kg
Cooling Fan-cooled, speed controlled
Protection Short circuit, automatic current/power limiting,
input/output overvoltage, thermal
Alarms Fan failure, Short circuit/arcing protection,
High temperature/output voltage Low output voltage,
Input voltage out of range Low fan speed (warning)
Internal communication failure
LED Indication Green: AC normal operation
Yellow: Steady - Low fan speed, High temperature
Flashing - Communications failure
Red: Module alarm / shutdown
Audible noise <45dBA @ ≤25°C (50% load) | <60dBA (100% load)

NOTE For details of FMP20.48 and FMP30.48C available only in APAC region please
see individual datasheets.
2.3 System Components

With the exception of the rectifier modules the Guardian Access 3U system is delivered with
all components mounted according to the ordered configuration. The main components are
described below and in later chapters of this manual.
2.3.1 System Controller

The Guardian power system can be controlled by the ACX Advanced or PCC controller.
The description and operation of these controllers is covered in separate manuals which
are available at:
ACX Advanced: https://www.unipowerco.com/pdf/acx-man.pdf
PCC: https://www.unipowerco.com/pdf/pcc-man.pdf
2.3.2 DC Distribution Unit

The distribution unit includes configurable load breakers, battery breakers, a shunt for
battery current measurement and fuse alarms for load and battery breakers.
The distribution unit has no special operation other than switching the load and battery
breakers on and off. All trip states of breakers are supervised by measuring the voltage
drop across each breaker.
Breakers that are not connected to any load will not cause a breaker alarm even if they
are left open.
A battery fuse alarm may not be triggered instantly when a battery breaker is off. The
alarm is triggered only when the voltage drop between the system voltage and the battery
voltage is more than 1.5V. The interval that the voltage drop increases to 1.5V depends
on the battery status.
Due to a small leakage current (2.5-3mA) through the alarm circuit, the voltage measured
with a Digital Volt Meter (DVM) on an open breaker output will be nearly equal to the
rectifier output voltage.
The distribution module has common “+Ve” with load breakers in “-Ve” leg. For more
information see schematic drawing in Appendix A - Drawings.

2.3.2.1 Low Voltage Disconnect (LVD) and Dummy LVD

Generally, the system is equipped with low voltage battery disconnection, which prevents
the batteries from deep discharging, thus prolonging the battery life. A disconnection
requires a detected mains failure at the supervision unit.
If disconnection occurs, the batteries will not supply power to the load until they have
been recharged to set voltage level, which can be adjusted by the user.
If disconnection occurs, the batteries will be reconnected when mains supply returns.
A dummy LVD can also be installed into the power system if the Low Voltage
Disconnection function is not needed.
2.3.2.2 Partial Load Disconnection / Load Shedding (PLD)
Partial load disconnection can be configured to be voltage or time dependent, this is
selected when ordering the power system.
At a mains outage the controller will open the PLD contactor when the batteries have
discharged 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.
2.3.3 Rectifier Module

The fan-cooled rectifier converts the AC input to -48VDC output for loads and batteries.
It is designed for parallel operation and plug-in installation in the power shelf and supplies
extremely stable DC power.
Each rectifier incorporates an internal microprocessor that sends frequent updates to the
system controller and adjacent rectifiers. This ensures accurately controlled load sharing
among rectifiers and supplies status and identification information to the controller.
The rectifier module features two LEDs for status indication, thermal protection with
power derating, and input over voltage disconnection with automatic reset. The rectifier
module is hot-swappable and can be quickly removed and replaced without disrupting
the system or load.
Handles
Cooling Fans
Status LEDs
Figure 2-5 Guardian Rectifier

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 qualified personnel.
• Always keep tools away from walkways and aisles. Tools present a tripping hazard
in confined areas.
• Keep the system area clear and dust-free during and after the installation.
• Always know the location of emergency shut-off 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.

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 specifications sheet to determine
whether the install site meets all the size, environmental, and power requirements.
• The system should only be moved by qualified 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

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.

3.1.7 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 specifications 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 specifications of the system. In
addition, equipment connected to the system should not overload the circuit breakers
as this may have a negative effect on overcurrent protection and supply wiring, causing
system or user harm.
• Verify the DC capacity before making connections. See system specifications 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.

3.1.8 Grounding
WARNING Grounding connection must be performed before operating the system.

Refer to local codes, e.g. ANSI, CEC, NEC, T1-333, ETSI 300-386-TC specifying the
connection of power system to building ground. In case of any doubt regarding the
grounding connection, please contact a person responsible for the system.
WARNING The system should be hard-wired to the incoming earth ground. A solid high
current ground connection capable of sinking the maximum system current is required.
CAUTION A conductor is connected between the ground point and the 0 VDC bus bar
on the PBDU distribution. This conductor is connected to its own earth bar and not shared
with other safety conductors.
3.1.9 Batteries
WARNING When installing or replacing batteries, there is risk of explosion if an incorrect

battery type is used.
3.1.9.1 Lead Acid Batteries
WARNING This equipment may use Lead Acid Batteries. When handling batteries,
follow the instructions included with the battery set, as the fluids contained within these
batteries are known to be a health hazard. The disposal of lead acid batteries is subject to
legal requirements for hazardous waste disposal. Local guidelines should be followed for
disposal.
Ensure the following guidelines are observed when dealing with equipment that may contain
lead acid batteries:
• Any attempt to burn these batteries may result in an explosion and the generation of
toxic fumes.
• Should a lead acid battery suffer damage, it must be moved into a well-ventilated area.
Contact with the corrosive fluid must be avoided.
• Neutralize any acid corrosion with copious amounts of a solution of baking soda and
water, and then wipe off all traces of soda.
• If the lead acid battery is removed from the equipment, any exposed contact must be
insulated prior to disposal.
• Ensure that protective full-face shields, rubber gloves and aprons are worn and
insulated tools are used when working with the batteries. It is advised also to have
water available in case acid gets in contact with the eyes.

3.1.10 In Case of an Accident

In the event of an accident resulting in injury:
1. Use caution and check for hazards in the area.
2. Disconnect power to the system.
3. If possible, send someone to get medical aid. If not, check the condition of the victim
and call for help.
3.2 Caution
3.2.1 Storage and Transportation
CAUTION During storage and transportation, the units must remain in their original
packages in order to avoid mechanical damage, maintain tracability, and protect the units
against electrostatic discharge.
3.2.2 Disposal
CAUTION The product should not be disposed with other wastes at the end of its working
life so as to prevent possible harm to the environment or human health from uncontrolled
waste disposal.
3.2.3 Handling Electrostatic Sensitive Devices
CAUTION An electrostatic sensitive device is an electronic component that may be

permanently damaged by the discharge of electrostatic charges encountered in routine
handling, testing and transportation.
3.2.4 Traceability
CAUTION Units are labeled with permanently attached product identification labels.
The labels are designed to be indelible throughout the life span of the equipment, unless
mistreated. Make sure that the product identification labels are present on the equipment
and are not subjected to unusual wear or mistreatment.

3.2.5 Breakers
Maximum 45°C operating ambient:
1. UP to 32A CB maximum load must not exceed 80% of it’s rating.
2. 40A CB maximum load shall not exceed 30A.
3. 50-63A CB maximum load shall not exceed 35A.
1. Up to 20A CB maximum load must not exceed 80% of it’s rating
2. 25A to 63A CB maximum load must not exceed 60% of it’s rating.
1. Up to 20A CB maximum load must not exceed 80% of it’s rating
2. 25A to 63A CB maximum load must not exceed 50% of it’s rating.
CAUTION Breakers should always be replaced with the same type and rating in order to
avoid damage to system components.
3.2.6 Hot Surfaces
CAUTION Areas of the Power System may become hot. Take precautions and handle
with care to avoid bodily harm.

Chapter 4 Installation Guide
4.1 Preparation
4.1.1 Installation Overview

The following is the recommended sequence for the installation procedures. The sequence
may change according to job or actual configuration.
• Unpack and check that all the equipment and materials have been delivered.
• Obtain the recommended tools.
• Check the connecting cable size.
• Mount the power system subrack to a cabinet or an open frame.
• Remove the top cover and knockouts for cable entry (if extension cover kit is ordered).
• Connect the earth grounding cable.
• Connect the AC input power.
• Connect the loads to the Distribution Unit as required.
• Connect the battery cables between power system and batteries.
• Connect the external alarm, symmetry cable and temperature sensor cable as required.
• Connect the RS232 communication cable (if RJ45-DB9 cable is ordered).
• Insert the rectifiers into the rectifier frame.
• Reinstall the top cover (If cover kit is ordered)
4.1.2 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.
Report any parts that are damaged, missing or incorrect. If possible, correct the problem
before continuing.

4.1.3 Tools
The following tools are required for a safe installation of the system:
• Anti-static hand strap.
• Socket wrench, insulated.
• Screwdriver set, flat, insulated.
• Screwdriver set, torx, insulated.
• Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated.
• Torque spanner (for battery connection), insulated.
WARNING Use only single-ended, fully insulated tools. Shafts of screwdrivers etc.
should be insulated.
CAUTION Installation in USA / Canada must conform with the requirements in

NEC/CEC.
CAUTION Care must be taken when installing this system. The units can be damaged
and can cause damage if not handled with care. Pay particular attention to the order in
which units are installed.

4.1.4 Cable Size

Please use the recommended cable size given below for the system installation.
Port Current Cable Size Cable Size Temperature

Max. Min.(mm²) Min.(AWG) Rating
AC Input -L1 32A 10mm² 7 AWG 105°C
AC Input -N 32A 10mm² 7 AWG 105°C
AC Input -PE - 10mm² 7 AWG 105°C
Battery MCB 80A 20mm² 4 AWG 105°C
DC Load -MCB 63A 16mm² 5 AWG 105°C
DC Load -MCB 40A 10mm² 7AWG 105°C
DC Load -MCB 10A 2.5mm² 14 AWG 105°C
Table 4-1 Recommended Electrical Cable Size
Circuit Breakers must not exceed the below loading based on maximum 55°C operating
ambient:
• For load breaker rated 5 to 32A, the maximum load must not exceed 80% of rating value.
• For load breaker rated up to 63A, the maximum load shall not exceed 40A if space is
provided between breakers. Maximum 30A is allowed if no space provided.
• For battery breaker rated up to 80A, the maximum load shall not exceed 80% of rating
value.
• For battery breaker rated 100 to 125A, the maximum load shall not exceed 75A.

4.2 Rack Mounting

There are two mounting brackets installed on the front left and right side of the power system
to enable you to securely fasten the sub-rack to a cabinet or an open frame.
NOTE For ease of mounting the power rack it is recommended to remove the rectifiers.
NOTE When mounting the system to an open frame, the brackets should be moved to the
middle position.
To mount the subrack into a cabinet, follow the steps below:
1. Determine the installation position according to system measurement. Refer to the
Appendix A for details. Re-install the mounting bracket in another position if necessary.
Refer to the figure 4-1 below.
Two ways to install mounting

brackets in the front position
Figure 4-1 System Mounting - Cabinet
2. Place the system into the cabinet.

3. Fasten the system into the cabinet by using four M6 x 12mm screws and mounting
brackets on the front left and right side of the unit. Tighten the screws to 6 Nm.

To mount the system into an open frame, follow the steps below:
1. Determine the installation position according to system measurement. Refer to the
Appendix A for details.
2. Remove the mounting brackets on the front left and right side of the system.
3. Refix the mounting brackets to the middle left and right side of the system.
4. Place the system into the open frame.
5. Fasten the system to the open frame by using four M6 x 12mm screws and the mounting
brackets. Tighten the screws to 6 Nm.
Figure 4-2 System Mounting - Open frame / relay rack

4.3 Cable Entry

If the Rear and Top Cover Kit or Extended Rear and Top Cover Kit is installed on the power
system, the top cover should be removed for connecting AC, DC, alarm and temperature
sensor cables.
4.3.1 Remove Top Cover

To remove the top cover of Rear and Top Cover Kit, follow the steps below:
1. Remove the front panel of the Distribution Unit by loosing two screws.
2. Push the top cover backward and then lift to remove the it.
Top Cover
Front Panel
Figure 4-3 Remove Top Cover
To remove the top cover of Extended Rear and Top Cover Kit, follow the steps below:
1. Remove the front panel of the Distribution Unit.
2. Push the top cover backward and then lift to remove it for access to the DC and alarm
connection.
3. Remove the AC input cover of the Extension Rear and Top Cover Kit for access to the
AC connection.

Top Cover
Front Panel
AC Input Cover
Figure 4-4 Remove Top and AC Input Cover
4.3.2 Cable Entry Openings

The Extended Rear and Top Cover is designed with two knockouts and one circular opening
for AC cable entry plus and three larger openings for DC and alarm cable entry.
When connecting and routing the AC cable from the right hand side or the bottom, first
remove the knockout, then install the supplied PG21 to fix the AC cable.
Figure 4-5 below depicts three types of AC and DC cable entry.
AC cable entry from rear AC cable entry from side AC cable entry from bottom
DC cable entry from rear DC cable entry from rear DC cable entry from bottom
Figure 4-5 Cable Entry Options

4.4 Grounding Connection

Earth grounding connection is essential before connecting to the AC supply.
The positive DC busbar is connected to the grounding point in the rear of the system using
a copper bar.
1. Switch off all breakers on the distribution panel.
2. Connect an insulated cable with a cross-sectional area of 16mm² (5AWG) between the
earth connection point of the system and the Main Earth Terminal (MET).
3. Tighten the cable connection to a torque of 8 Nm.
Figure 4-6 Grounding Connection
If the Extended Rear and Top Cover Kit is installed on the power system, another earth
grounding point on the rear cover is supplied for convenient connection and cabling. Figure
4-7 below depicts how to connect the earth grounding cable to the rear cover.
Figure 4-7 Grounding Connection with Extended Rear Cover - Two Point

Figure 4-8 Grounding Connection with Extended Rear Cover - Single Point
4.5 AC Input Connection
WARNING Ensure that mains input is turned off before connecting. The grounding must
be connected to PE terminal as first.
WARNING High leakage current. Ensure earth is connected before connecting mains
supply.
WARNING Only a qualified electrician may carry out the mains installation.
CAUTION Depending on deployment region with regards to lightning strikes and heavy
inductive energy, it is highly recommended to install AC Surge Protection Class C, if not
delivered with the system..
WARNING Used cable must be inserted into the terminal with as little insulation removed
as possible, so as to prevents any stranded conductor coming loose and touching any other
conductive parts. Tighten terminals securely with torque 1.5-1.8Nm.
1. Strip the AC input cable conductors to the correct length for connection to the terminals.
2. Route the AC input cable through the AC cable entry and connect the cable to the AC
terminals and tighten the screws to 1.5 - 1.8 Nm.
3. The mains input terminal blocks can be connected to:
• 1-phase 110VAC or 230VAC (Figure 4-9)
• 3-phase 110/190VAC or 230/400VAC (Figure 4-10).

LI L2 L3 NI N2 N3 PE PE
2.0 Nm + 10%
Figure 4-9 AC Input Terminal Block (1-phase)
Recommended mains breaker:

100-120VAC 1W+N+PE or 208-240VAC 1W+N+PE or 200-240VAC 2W+PE:
UL listed, Single pole 3 x 50A C-characteristics.
LI L2 L3 NI N2 N3 PE PE
2.0 Nm + 10%
Figure 4-10 AC Input Terminal Block (3-phase)
Recommended mains breaker:

360-416 V AC 3W+N+PE: UL listed,Three pole 50 A C-characteristics.

4.6 DC Load Connection

Before connecting DC load cables, check that the cable rating is matched with selected the
MCB and/or load.
1. Check that all the load MCBs are in the OFF position.
2. Connect the negative (-) cable from the load to the relevant -48 V circuit breakers. Insert
the stripped cable into the opening on top of the terminal and tighten the screw to 3.0 Nm.
3. Connect the positive (+) cable from the load to the relevant positive terminal on the bus
bar. Insert the stripped cable into the opening on top of the terminal and tighten the screw
to 3.0 Nm.
4. The loads connected to the bus bar should be started from the left.
Load 0V
Load -48V
Figure 4-11 DC Load Connection

4.7 Battery Connection

The battery cables are not delivered with the system.
1. Check that all the battery MCBs are in the OFF position.
2. Connect the “+” cable of each battery string to the positive bus bar of the system. Tighten
the cable terminal to 3.0 Nm.
3. Connect the “-“cable of each battery string the battery circuit breaker. The copper bar
with washer and nut installed on the circuit breaker is used to connect and tighten the
battery cable lug.
4. Connect the other ends of the battery cables to the “-“and “+” terminals of the batteries.
Refer to Table 6-1 in the Maintenance and troubleshooting chapter for correct torque.
Battery 0V
Battery -48 V
Figure 4-12 Battery Connection
4.8 Alarm and Signal Connections

There are three kinds of alarm interface board for selection to meet the user’s requirement.
• PCC External Board: Select this if the PCC internal communication board is selected.
• ACX External Board: Select this if the ACX internal communication board is selected
and a maximum of 4 alarm relay outputs are required.
• ACX Relay Board: Select this if the ACX internal communication board is selected and
5 - 10 alarm relay outputs are required.

External Alarm Interface

(BM0723)
-12V 3 Red
J1 Multi-purpose -24V 2 Green Symmetry #1
-36V 1 Blue
26
J10 J2 Multi-purpose -12V 3
-24V 2
-36V 1
+5V 3 Red
Green Temperature
J4 Temparature Sensor 2 Blue sensor
1
0V
NO1 3
J6 Alarm1 NC1 2
C1 1
NO2 3
J7 Alarm2 NC2 2
C2 1
NO3 3
J8 Alarm3 NC3 2
C3 1
J9 Alarm 4 NO4 3
NC4 2
C4 1
Figure 4-13 PCC External Board
Blue
1
Green
2 Symmetry#1
XC2 Red
3
Multi purpose 1-6 4 Blue
Green Symmetry#2
5
6 Red
7
XC3 8
Multi purpose 7-12 9
10
11
12
0V 1 Blue
TEMP1(BATT) 2 Green Temperature
3 Red sensor
+5V
XC4 4 Blue
0V
5 Green Temperature
TEMP2(AMB)
6 Red sensor
+5V
3
2
XC5 Alarm 1 1
6
Digital In 1
5
Digital In 2 XC7
Alarm 2 4
+5V
GND 3
2
Digital out 1 Alarm 3 1
Digital out 2 XC8 XC6
6
+V
5
50 GND
Alarm 4 4
XC1
Figure 4-14 ACX External Board

Blue
1 1
Green
2 Symmetry#1
2 K2 XC2 Red
3
3 Multi purpose 1-6 4 Blue
4 XC9 Green Symmetry#2
5
6 Red
5 K1
6 7
XC3 8
1
Multi purpose 7-12 9
2
K3 10
3
11
4 XC10 12
5 0V 1 Blue
K4
6 TEMP1(BATT) 2 Green Temperature
3 Red sensor
1 +5V
XC4 4 Blue
2 0V
K6 5 Green Temperature
3 TEMP2(AMB)
XC11 6 Red sensor
4 +5V
5 K5 3
6 2
XC5 Alarm 1 1
6
Digital In 1
5
Digital In 2 XC7
Alarm 2 4
+5V
GND 3
2
Digital out 1 Alarm 3 1
Digital out 2 XC8 XC6
6
+VR
5
50 GND
Alarm 4 4
XC1
8
8 XC13
XC12
Figure 4-15 ACX Relay Board
The alarm interface board is located in the top right side of the system. To connect the alarm
cable to the alarm interface board, follow the steps below:
1. Remove the green plug from each connector.
2. Determine whether to reference normally closed or normally open with reference to
common for each alarm contact.
3. Strip the wires back approximately 10mm. Stranded wire may be soldered or covered
with copper ferrule if desired.
4. Insert the wire into the top openings of the green plug and tighten the screw to clamp
wire.
5. Re-insert the green plug with the alarm cable into the alarm interface board.
NOTE The alarm configuration will be dependent on your system configuration.
NEED MORE INFORMATION? For detailed information regarding Alarm connection

see Appendix A, Installation Drawing.

4.9 Symmetry Connection

The ACX controller can supervise 4-block symmetry measurements on 4 battery branches.
If the PCC controller is used, only 2 battery branches can be measured on 4 blocks.
NOTE Symmetry cables are pre-connected to the system.
NOTE Multi Purpose inputs which are not used for symmetry measurement can be
reconfigured to user defined analog inputs.
1. Insert a suitably sized cable lug into one pole of the inter-block connection plate. Fasten
the lugs and plates to individual battery poles.
2. For 2-block battery symmetry measurement fix one wire of the symmetry cable to the
cable lug in the mid-point of the battery string, see Figure 4-16.
Figure 4-16 2-block Symmetry Measurement (for illustration only)
For 4-block measurement fix the 3 wires (red, green and blue) of the symmetry cable to
individual cable lugs. Color coding of the cables must be followed for proper symmetry
measurement, see Figure 4-17.
Figure 4-17 4-Block Symmetry Measurement (for illustration only)

NOTE The interblock Connection Kit is not delivered with the system.
4.10 Temperature Sensor Connection
NOTE The power system is usually delivered with pre-connected temperature sensor
cables. If not, use a three-pin plug and connect according to the Appendix A - Installation
Details.
Battery Temperature
Temperature sensor 1 measures the temperature of the battery bank while the controller
adjusts the float charge voltage according to the temperature compensation factor set in the
controller. This factor must be set in the controller according to the battery manufacturer ‘s
recommendations.
Fasten the temperature sensor in the middle of the battery bank, Figure 4-18.
Temp. Sensor
Figure 4-18 Temperature Sensor Connection
NOTE The temperature compensation factor can be set only for temperature sensor 1.
Ambient Temperature
Temperature sensor 2 allows a second temperature reading, most commonly the ambient
temperature around the system. Place the sensor as required.
The temperature is displayed in the External Measurements menu in the ACX controller or
in PowCom™ software.
NOTE Temperature sensor 2 can be activated only in the systems with the ACX
controller installed.

4.11 Connecting an RS232 Communication Cable

The controller can communicate with an external device such as a network interface card
through an RS232 connection.
1. Remove the top cover of the controller.
2. Connect the RJ45 port of the RS232 communication cable to the RJ45 port marked with
RS232 on the internal communication board.
3. Pull out and fix the DB-9 connector of the RS232 communication cable for application.
4. Re-install the top cover of controller.
DETAIL A
Figure 4-19 RS232 Connection
4.12 Rectifier Installation
NOTE Ensure that the rectifier handle is in the OPEN position (forms 35-40° angle with
rectifier body) before inserting the module into the slot.
Rectifier module should be installed starting from the bottom left position in the rectifier
shelf.
NOTE If you ordered a power system with 3 rectifier positions, leave the bottom two
slots blank and install the rectifier from the middle left position.
1. Place the rectifier module in the mounting slot with handle facing out.
2. Slide the rectifier module into the slot until it contacts the interface connection at the rear
of the shelf, Figure 4-20 #1.

3. Fully insert the rectifier by pushing the handle towards the shelf. The rectifier handle will
rise up and lock the rectifier into the position, Figure 4-20 #2.
4. Repeat steps 1 to 3 if more rectifiers are to be installed.
Figure 4-20 Rectifier Installation
4.13 Reinstalling Top Cover

After completing all connections, reinstall the top cover if the Rear and Top Cover Kit is
ordered.
1. Place the top cover on the top of the Distribution Unit. Make sure that the to cover and
Distribution Unit are matched well.
2. Install the front panel of Distribution Unit so that the top cover is fixed and unremovable.
3. If the Extended Rear and Top Cover Kit is ordered, reinstall the AC input cover on the
back of the unit.

Chapter 5 Commissioning
5.1 Commissioning Overview

Before delivery the system was thoroughly inspected and tested. The following chapter is a
guide to the set-up and operation of the control functions of the system.
NOTE Before starting commissioning read the product description for the individual
components.
WARNING ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE

AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING. IT IS IMPORTANT
TO FOLLOW ALL SAFETY REGULATIONS.
If there are any difficulties in increasing the voltage to alarm level, the alarm level can be
adjusted to a lower level.
5.2 Tools and Test Equipment
5.2.1 Tools List

The essential commissioning tools are listed in the Installation chapter.
5.2.2 Test Equipment

• Multimeter (3½ Digit, 0–1%DC)
• Load resistance, to fully load of two rectifiers
5.3 Preparation
Check the installation to ensure the following:
• Grounding: The equipment is correctly grounded. The grounding cable size, color and
routing conform to the requirements.
• Power: The incoming mains AC power is available for this site. The site power switch
and circuit breakers are clearly labeled. The power cables are correctly terminated.
• The site is clean and safe. Check that the system/cabinet is free of any unwanted objects
or insects that may have got in during the installation.

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. Ensure that load and battery MCB breakers are set to OFF position - ensuring the load
and battery strings are connected.
3. Ensure that all rectifier modules are removed. If not, remove each one in turn starting
from the rightmost position.
4. If the rectifier subrack has dip switches for addressing, verify that the dip switches are
set correctly.
5. Check the battery polarity with the multimeter (3½ Digit, 0·1% dc). Place the positive
lead of the meter to the positive busbar and the negative lead to the battery breaker. The
meter must now show a positive voltage. If the voltage is negative, change over the
connection of the blue and black battery cables to the batteries.
6. Turn on the AC mains voltage.
7. Measure the AC voltage on the AC terminal block between phases and neutral. The
correct value is approximately 230V. If the value is different, check the AC connection.
8. Plug in all rectifier modules, starting from the leftmost position. Make sure to fasten the
rectifiers again. The rectifiers will turn on automatically.
9. Set all load breakers into the “1” (ON) position.
10. The green LED on the controller should blink for approximately 20 sec.
11. The output voltage will increase slowly to U1 (float charge voltage).
12. Turn the battery breaker(s) to the “1” (ON) position.
13. Set the battery current limit according to the battery manufacturers requirements.
14. If any alarms are present, they should be reset in accordance with the procedure for the
installed controller, ACX or PCC.
15. The system should now be without alarms.
16. Attach all the system covers in their correct places.
17. Check that all changes to drawings, if any, have been completed.
18. Clean the site.
19. Fill in the commissioning record (see end of chapter).

5.5 Test of output voltage
5.5.1 Float charge (U1)

Ensure that the controller is operating.
Connect a load, approx. 50% of total capacity, to the system.
Check the voltage according to the battery manufacturer’s requirements. If the batteries
require a different float charging voltage, adjust the output voltage from the controller. (See
the section for the appropriate controller)
If no change is required, use the following values:
Battery type Float charge Boost charge

Open lead-acid batteries 2.23 V/Cell 2.33 V/Cell
Valve regulated lead-acid batteries 2.27 V/Cell -
Table 5-1 Float/Boost Charge Voltages
5.5.2 Adjustment of Float Charge, U1

Unless otherwise ordered the default output voltage is factory pre-set to 53.5V. The total
voltage has to be in accordance to the number of battery cells.
Please verify number of cells and the battery manufacturers requirement.
Adjust the output voltage from the control unit as necessary.
5.5.3 Boost charging (U2) (if applicable)

Open lead-acid batteries.
Automatic boost charging - calculation based on the time the battery voltage has been below
certain levels. Automatic activating of boost charging for this calculated time multiplied by
a (boost) factor.
Activate boost charging from the “Set/select U1-U4” menu in the controller.
Return to float charge manually by selecting “U1”, or automatically after a pre-set time.
VRLA batteries.
Most of the manufactures of valve regulated lead acid batteries do not recommend boost
charging. If this type of battery is used, the boost function should be disabled.

Boost charging figures

Observe and write down all of the boost charging figures. Parameters to be read/set/adjusted
from control unit or PC with PowCom™ installed.
5.6 Battery supervision

For systems with symmetry cables supplied:
Set the number of battery strings according to the number of battery strings in the system.
The settings are to be made in the control unit via a PC with PowCom™ installed or directly
in the controller (if symmetry failure is indicated).
The symmetry fault alarm can be simulated by pulling out one symmetry cable from the
battery string. Measure that setting to make sure that it is in accordance with the battery
manufacturer’s recommendations.
For systems with temp. probe cable supplied:
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).
5.7 Battery test

Settings should be made according to the battery manufacturer’s requirements, but as a rule
of thumb the following settings can be used for standard VR lead batteries:
No. of test pr. year = 2
U3 Test = 1,9 V/cell
End voltage b.test = 1,94V/cell
Batt. test time = 40% of expected backup time
Ah limit for test = 40% of nominal battery capacity
Parameters should be set/adjusted from the controller (Battery test menu) or “Supervision -
Set parameters” menu in PowCom™.

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.
Checked Result
()
1 Check that the rack is level
2 Check that all breakers are turned to “off”
position and that no rectifiers are mounted in the
subrack(s).
3 Connect AC, and measure voltage on the mains L1-N:……….V AC
input connections in the cabinet, Is to be 230V
AC (Measure 230V from phase to N when 400V L2-N:...............V AC
mains input is used) L3-N:...............V AC
4 Mount the rest of the rectifiers
5 After connection of battery, verify right polarity
by measuring the voltage drop across the battery
breakers (normally not more than 5V DC).
6 Check float charge, U1, and boost charge, U2. U1:…….V DC
It is to be adjusted according to the battery
manufacturers requirements. U2:.........V DC
7 Check temperature compensation. It is to be
adjusted according to the battery manufacture
Comp.:…….V/10°C
requirements.
Read off:………°C
Check temperature read from the controller
compared to the ambient temperature.
8 Check symmetry measurement and set number Number: ….
of battery strings according to actual number of
supervised battery strings in the system. Alarm limit:……
9 Check alarm transmission by running an alarm
test.

Table 5-2 Commissioning Record

Chapter 6 Maintenance & Troubleshooting
6.1 Maintenance
6.1.1 Checking Terminal Connection

The connections on the terminal blocks and circuit breakers must be checked according to
the Table 6-1 at least once a year.
TYPE OF CONNECTION MODEL / DESCRIPTION TORQUE TORQUE

(Nm) (Inch LB)
Terminal block for rail AKG 16mm² 2.5 22
Terminal block for rail AKG 35mm² 3.5 31
Front terminal for copper cables FC Cu T2 95mm² 7.0 62
Terminal block Weidemullers WDU 4mm 0.6 5
Miniature circuit breaker Siemens 2.5 22
Miniature circuit breaker Merlin G 3.5 31
Miniature circuit breaker ABB 2.0 18
Miniature circuit breaker CBI HY-MAG 3.0 27
Molded case circuit breaker ABB 160A - S2 5.0 45
Molded case circuit breaker ABB 160A/250A - S3/S4 9.0 80
Molded case circuit breaker ABB 630A - S6 9.0 80
Molded case circuit breaker Terasaki - XS125CJ 9.0 80
Connection unit for 2 or 3 pole breaker Merlin G & Siemens 13.5 120
Terminal Block Phoenix Phoenix Mini Combicon 0.25 2
Terminal block Phoenix UK10 / UKLKG10 1.5-1.8 13-16
Terminal block Phoenix UK16 / USLKG16 1.5-1.8 13-16
Terminal block Phoenix UK35/UIK35/USKG35/UISKG35 3.2-3.7 28-33
Miniature circuit breaker Nadar 2.5 22
Table 6-1 Connection Torque Setting Check
6.1.2 Other Requirements

At least once a year the output voltage should be verified to be within acceptable limits. The
result of the test should be recorded and filed to see any deviations.
In addition, the system requires periodic inspections and routine cleaning. It is very important
to keep the all areas and components of the system free from dust or other unwanted objects
to ensure free air circulation and safe operation of the system.

6.2 Troubleshooting
This troubleshooting chapter helps to determine the cause of the problem and suggests
possible repair solutions. 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
the Alarms/Messages section of the appropriate controller manual:
ACX Advanced: https://www.unipowerco.com/pdf/acx-man.pdf
PCC: https://www.unipowerco.com/pdf/pcc-man.pdf
By default, alarms are set to be indicated with a red light (higher priority) and messages
with a yellow light (lower priority).
Fault Possible Cause Suggestion/Solution

Low System Module failure. Replace faulty module.
Voltage
Loss of AC power. Verify AC input connection.
Load exceeds module capacity. Add module to system.

High System Module failure. Replace the faulty module.
Voltage
System voltage exceeds the set limit. Check the High Voltage Alarm limit
setting.
Mains Error AC supply OFF on one rectifier in the Verify that the AC input breaker is
system with one plugged in rectifier. ON.
AC supply OFF on at least two Verify AC input connection.

rectifiers in the system with minimum
two plugged in rectifiers.
AC Low Voltage AC voltage drops below the set limit. Verify the Low AC voltage limit
setting.
Verify AC Input connection.
Verify AC Input voltage.

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


Module Failure Faulty module. Check if module sends alarm flag.
AC OFF on a single rectifier (if more Verify the AC voltage to the failed
than one rectifier is installed). module.
Rectifier current sharing fault. Re-insert the faulty module, wait for
30 seconds
Low DC output voltage, overvoltage
shutdown, module fan failure, module Replace the faulty module.
is overheated.
Urgent Module More than one rectifier is reporting See Module failure alarm.
Failure Module failure.
High Load Faulty module . Compare the load current with
installed rectifier capacity.
Rectifier load current exceeds the set
High load limit [%]. Add a rectifier or reduce load.
Verify the High load limit setting.
Replace the faulty module.

Overvoltage Faulty module Re-insert the module, wait for 5
Shutdown minutes.
Replace the faulty module.

Load/Battery System voltage drops below the set Check the battery condition.
Disconnection limit.
Check the AC mains connection.
System shutdown.
Check the input breaker.
Check the rectifier modules.


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.
communication wire.
Verify that the communication cable
is properly connected and it is not
damaged. Replace if necessary.
If the board address does not

communicate, check if it is installed
in the system. If it is, replace the
board.
If there is a non-communicating
module or unit, remove the non-
communicating address from the
controller (Accept removed parts).
Do so only if you are sure you do not
use them any more.
Verify, if the controller is operating

properly. If not, replace the
controller.
Distribution Tripped load breaker / blown load Verify there is no short circuit in load
Fuse Failure fuse. cabling.
Reset the breaker, if it trips again,

there is a problem with the load or a
breaker itself.
Replace the breaker / fuse if

necessary.
Battery Fuse Tripped load breaker / blown load Verify there is no short circuit in load
Failure fuse or battery cabling.
Verify the breaker / fuse is correctly

rated.
Reset the breaker, if it trips again,

there is a problem with the load or
battery or a breaker itself.
Replace the breaker / fuse if

necessary.


Symmetry Fault Battery at end of life. Verify the battery condition.
Wrong symmetry cable connection. Verify the symmetry cable

connection.
Wrongly set Symmetry limit value.
Verify the Symmetry limit value.
Low Battery Battery temperature drops below the Check the heating of the system.
Temperature set Low battery temperature limit.
Check the ambient temperature
(it should not be lower than
recommended battery temperature).
high Battery Battery temperature exceeded the set Check the cooling or ventilation.
Temperature limit.
Verify the battery condition.
Check the Battery Current Limit.

Temp. Probe The temperature probe is not properly Verify the temperature probe
Failure connected to the system. connection.
Faulty temperature probe. Verify the internal / external

temperature via controller front panel.
Temperature probe wire is
interrupted. Replace the faulty probe with a new
one.
Temperature difference between the
controller temperature and the probe Identify the root cause of the hot
temperature is greater than 60°C. environment at the batteries and/or
controller.
Alarms Blocked Alarm is manually activated by the Needs to be manually turned OFF to
(only with LCD serviceman on the site (used during allow the alarms to be displayed
display) system servicing, no other alarm is
displayed)
If none of the above solves the problem please contact customer support, see section 1.4.

Chapter 7 Replacing Modules
1
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, Figure 7-1 (1).
2
1
Figure 7-1 Unlocking and Removing the Controller
2. Pull the controller out of the shelf, Figure 7-1 (2).

3. Reverse the process to insert the new controller into the empty slot and fasten the screw.
CAUTION After controller start-up, verify if the appropriate configuration file is uploaded
to the controller. If necessary refer to the PowCom™ User Guide.
7.2 Rectifier Replacement
NOTE Rectifiers can be hot-swapped.
This section describes how to replace a faulty rectifier in an active system.

1. Release the rectifier handles and remove the faulty rectifier.
2. Insert the new rectifier into the slot and fasten it with the handles. Refer to section 4.12
of this manual for details.
3. Ignore the module alarm caused by current sharing.
4. After 1 minute the yellow LED starts blinking. Wait for a maximum of 4 minutes for the
indicator to stop blinking.

7.3 Battery and Load Breakers Replacement
WARNING Make sure the system is switched OFF.
The power rack is designed front accessible for easy maintenance. Battery and load breakers
can be replaced without removing the power rack from the cabinet.
This section describes how to replace faulty breakers.
1. Remove the front panel and the top cover as described in section 4.3.1.
2. Pull out the faulty breaker(s).
3. Install the correct breakers
4. Replace the front panel and the top cover as described in section 4.13.
7.4 Surge Protection Device Replacement
This section describes how to replace a faulty surge protection module.

1. Switch off AC input power.
2. Remove the top cover if the Rear and Top Cover Kit is installed.
3. Unscrew the retaining screw (1) and pull out the alarm interface board kit (2).
4. Pull out the failed surge protection module(3).
3
2
Figure 7-2 Replacing a Surge Protection Module
5. Insert a new surge protection module into the corresponding position.

6. Reinstall the alarm interface board kit and fasten the retaining screw.
7. Reinstall the top cover of power system.
8. Switch on AC input power.
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.

P O W E R I N G
System Layout Dimensions: 3U x 19" LVD:

CONTROLLER 200A 48V (for 5 pos system)
T E C H N O L O G Y
LOAD BREAKERS
USB ETHERNET (6 x 18mm configuration shown) CONTROLLER: OR
ACC or PCC (w/ethernet) with Display 125A 48V (for 3 pos systems)
OR
GUARDIAN 48
A.1 System Layout
Manual No. MS0027-MAN rev. 5

RECTIFIERS: Dummy LVD kits
FB1 FB2 FB3 F1 F2 F3 F4 F5 F6 5 x Guardain 48V (for 5 pos system)
OR PLD:
GUARDIAN 48
GUARDIAN 48
3 x Guardian 48V (for 3 pos system) 125A 48V
AC Distribution:
GUARDIAN 48
GUARDIAN 48
3-phase 3+1, Class C SPD optional
BATTERY
RECTIFIERS BREAKERS
DC Distribution:
Six configurations optional
1 x single pole battery breaker

AC CONNECTIONS SURGE SUPPRESSOR 13mm load breakers
Batt 1 1 2 3 4 5 6 7 8 9 10 11 12 13
(optional) LP
HP HP/LP Min. LP
ALARM & SIGNAL
LVBD & LVLD CONTACTORS CONNECTIONS 1 x single pole battery breaker
18mm load breakers
Batt 1 1 2 3 4 5 6 7 8 9
(see manual for details)
Page 51
LP
HP HP/LP Min. LP
2 x single pole battery breakers

13mm load breakers Batt 1 Batt 2 1 2 3 4 5 6 7 8 9 10 11
LP
HP HP/LP Min. LP

18mm load breakers
Batt 1 Batt 2 1 2 3 4 5 6 7 8
LP
HP HP/LP Min. LP

13mm load breakers
Batt 1 Batt 2 Batt 3 1 2 3 4 5 6 7 8 9
LP
HP HP/LP Min. LP
LOAD & BATTERY
CONNECTIONS 3 x single pole battery breakers
18mm load breakers
Batt 1 Batt 2 Batt 3 1 2 3 4 5 6
RS232 CONNECTION LP
(REMOVE TOP COVER HP HP/LP Min. LP
FOR ACCESS)
USB & ETHERNET
CONNECTIONS
Appendix A - Drawings
guardian_access_3u_ms27-man-rev5-0719.indd
A.2 Installation Details - Connections

Symmetry cable connections
Table shows different ways of battery symmetry cable connections depending on actual software (see controller software sheet)
0V Battery type: 2 blocks Battery type: 4 blocks

-12V (-)24V 0V
Battery symmetry 3 (-)12V red Battery symmetry 3
Battery -24V Battery -12V
White (-)24V green
string2. -36V
White
XC2 Battery symmetry 2 string1. -24V blue
XC2 Battery symmetry 2
0V -36V
(-)36V
0V Battery symmetry 1 Battery symmetry 1
-48V
(-)12V -48V red Battery symmetry 6
-12V (-)24V -12V
Battery Battery (-)24V green
-24V -24V Battery symmetry 5
string1. string2. (-)36V blue
-36V -36V
Battery symmetry 4
-48V -48V
Input mains terminals ACC Standard Alarm interface

Multi purpose 3
XC2 Multi purpose 2
single phase 120/230VAC Multi purpose 1
1 1 2 3 4 5 6 7
Multi purpose 6
XC2 Multi purpose 5
Multi purpose 4
Multi purpose 9
XC3 Multi purpose 8
PE PE N L Multi purpose 7
Multi purpose 12
2-phase 240VAC (N.A. / CALA) XC3 Multi purpose 11
1 1 2 3 4 5 6 7 Multi purpose 10
Temperature Battery
XC4
sensor Temperature
Temperature XC4 Ambient

PE PE L1 L2 sensor Temperature
3-phase 208/230VAC XC5 Alarm 1

(∆ connection)
1 2 3 4 5 6 7
XC5 Alarm 2
Alarm contacts
are shown in
alarm position
XC6 Alarm 3
PE L1 L2 L3
3-phase 400VAC XC6 Alarm 4
( Y connection)
GND
1 2 3 4 5 6 7
+5V
XC7 Digital Input 2
Digital Input 1
-Sys. Voltage Out
+Sys. Voltage Out
XC8
PE N L1 L2 L3 Digital Output 2
Digital Output 1

A.3 Block Diagram
0V
- Load 1
- Load n
Optional PLD
- PLD Load 1
- PLD Load n
shunt LVD
- Battery 1
- Battery n
J2
J1 Fuse alarm board(9948)
ACC internal board
1 0V
XC3 System voltage in ACC external board
2 -48V
1
8
XC2 2
8 3
XC7 RS485 XC10 CAN 50 Multi purpose 1-6 4
5
XC1 6
8 7
1 8
XC5 Door alarm XC3 9
2 XC8 RS232 Multi purpose 7-12 10
11
1 12
XC6 Surge arrestor alarm
2
XC4 +5V 3
1 shunt- Temp. 1 Sense 2
2 shunt+ 0V 1
Digital In 1 3
3 bat alarm 2
XC9-A Digital In 2 XC7
4 load alarm Alarm 1 1
+5V
5 LVD disconnect XC5 3
6 LVD reconnect
GND
2
XC2 Alarm 2 1
11 PLD disconnect Digital out 1
XC9-B 3
12 PLD reconnect Digital out 2 XC8 2
+V XC6 Alarm 3 1
GND 3
96
XC4
2
9 96 System voltage out Alarm 4 1
J2 J3 XC1
Ethernet
8 ACC
J1
USB
+ - + - + -
Subrack for Subrack for Subrack for
2xRectifier 2xRectifier 1xRectifier
Rectifier Rectifier Rectifier Rectifier Rectifier
L1 L2 L3 N N N PEPE
Applicable for 5 POS system
Surge protection module

A.4 Detailed Dimensions

15.02 ±0.02 (381.4±0.5) 4 x PEM S-M4-2 ZI or equiv.
14.43 ±0.02 (366.4±0.5) [both sides]
7.54 ±0.02 (191.4±0.5)
0.8 ±0.01
(20 ±0.3)
13.64 ±0.02 (346.4±0.5)
6.75 ±0.02 (171.4±0.5)
Dimensions: in. (mm)

(92.5 ±0.3)
3.64 ±0.01
Extended Cover
4 x Ø 0.25 (6.3) [6Nm max. torgue]

8 x PEM S-M4-2 ZI or equiv. [both sides]
19.07 (454.3)
5.22 ±0.01
16.04 (407.5) (132.5 ±0.3)
11.78 ±0.02 (299.2 ±0.5)
2.25 ±0.01
(37.7±0.3)
1.48 ±0.01
(57.1±0.3)
11.14 ±0.02 (282.9 ±0.5)
15.65 ±0.02 (397.4 ±0.5)
15.59 ±0.02 (395.9 ±0.5)
0.10 ±0.01 (2.5 ±0.2)
19.00 ±0.03 (482.5±0.8) GUARDIAN 48 GUARDIAN 48

17.64 ±0.03 (443.5±0.8)
17.38 ±0.03 (441.5±0.8)
18.31 ±0.03 (465.0±0.8)
GUARDIAN 48 GUARDIAN 48 GUARDIAN 48

FB1
FB2
FB3
F1
F2
F3
F4
F5
F6
Note: Extended Cover details are shown in green.

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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

Document Number: MS0027-MAN rev. 5 © 2019 UNIPOWER LLC

Copyright © 1999-2019 UNIPOWER LLC

REV DESCRIPTION CHK’d & APPR’d / DATE

Manual No. MS0027-MAN rev. 5 Page 2 guardian_access_3u_ms27-man-rev5-0719.indd

Manual No. MS0027-MAN rev. 5 Page 3 guardian_access_3u_ms27-man-rev5-0719.indd

4.3 Cable Entry...............................................................................................................................26

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Manual No. MS0027-MAN rev. 5 Page 5 guardian_access_3u_ms27-man-rev5-0719.indd

1. About This Manual

1.3 Document Key

CAUTION This symbol indicates a situation that might result in equipment

NEED MORE INFORMATION? This symbol is used to reference

Manual No. MS0027-MAN rev. 5 Page 6 guardian_access_3u_ms27-man-rev5-0719.indd

Table 1-1 Abbreviations

1.4 Product Support

Corporate office: Manufacturing facility: Manufacturing facility:

When contacting UNIPOWER, please be prepared to provide:

Manual No. MS0027-MAN rev. 5 Page 7 guardian_access_3u_ms27-man-rev5-0719.indd

Figure 2-1 Power System Overview

Manual No. MS0027-MAN rev. 5 Page 8 guardian_access_3u_ms27-man-rev5-0719.indd

Figure 2-2 Principal of Operation

Manual No. MS0027-MAN rev. 5 Page 9 guardian_access_3u_ms27-man-rev5-0719.indd

Manual No. MS0027-MAN rev. 5 Page 10 guardian_access_3u_ms27-man-rev5-0719.indd

2.2 System Parameters

Manual No. MS0027-MAN rev. 5 Page 11 guardian_access_3u_ms27-man-rev5-0719.indd

RECTIFIER MODEL FMPe20.48G FMP25.48G FMPe30.48G

Manual No. MS0027-MAN rev. 5 Page 12 guardian_access_3u_ms27-man-rev5-0719.indd

2.3 System Components

2.3.1 System Controller

2.3.2 DC Distribution Unit

Manual No. MS0027-MAN rev. 5 Page 13 guardian_access_3u_ms27-man-rev5-0719.indd

2.3.2.1 Low Voltage Disconnect (LVD) and Dummy LVD

2.3.3 Rectifier Module

Figure 2-5 Guardian Rectifier

Manual No. MS0027-MAN rev. 5 Page 14 guardian_access_3u_ms27-man-rev5-0719.indd

3.1 Safety Warnings and Guidelines

3.1.1 System Markings

3.1.2 Safety Recommendations

Manual No. MS0027-MAN rev. 5 Page 15 guardian_access_3u_ms27-man-rev5-0719.indd

3.1.3 Installation Warning

3.1.4 Restricted Access Area Warnings

3.1.5 System Enclosure

3.1.6 Operating Temperature Warnings

Manual No. MS0027-MAN rev. 5 Page 16 guardian_access_3u_ms27-man-rev5-0719.indd

3.1.7 Electrical Safety Warnings

Manual No. MS0027-MAN rev. 5 Page 17 guardian_access_3u_ms27-man-rev5-0719.indd

WARNING Grounding connection must be performed before operating the system.

WARNING When installing or replacing batteries, there is risk of explosion if an incorrect

3.1.9.1 Lead Acid Batteries

Manual No. MS0027-MAN rev. 5 Page 18 guardian_access_3u_ms27-man-rev5-0719.indd

3.1.10 In Case of an Accident

3.2.1 Storage and Transportation

3.2.3 Handling Electrostatic Sensitive Devices

CAUTION An electrostatic sensitive device is an electronic component that may be

Manual No. MS0027-MAN rev. 5 Page 19 guardian_access_3u_ms27-man-rev5-0719.indd

3.2.6 Hot Surfaces

Manual No. MS0027-MAN rev. 5 Page 20 guardian_access_3u_ms27-man-rev5-0719.indd