Unipower ARE-S Series User manual

Product Manual
for
ARE–S Series
48V and 130V Float Chargers
Single-Phase Input
PM990.1090.XX, Rev. 10
UNIPOWER, LLC
65 Industrial Park Rd
Dunlap, TN 37327
Phone: [phone]
Toll Free: 1-800-440-3504
Web site – www.unipowerco.com

ARE-S Series Chargers, Single Phase Front Matter
PM990.1090.XX, Rev. 10
i
RECEIVING INSTRUCTIONS
and
GENERAL EQUIPMENT INFORMATION
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS- This manual contains important safety and
operating instructions for the ARE-S Series units.
2. Before using the ARE-S Series unit, read all instructions and cautionary
markings on the unit, battery, and products using battery.
3. CAUTION- When used with batteries, use only lead-acid or nickel-cadmium
type rechargeable batteries. Other types of batteries may burst causing personal
injury and damage.
ATTENTION: Lorsque utilisé avec des accumulateurs, utilisez UNIQUEMENT des
accumulateurs acides plomb ou nickel–cadmium RECHARGABLE. AUTRES TYPES
DE BATTERIE peuvent causer, éclatement ET BLESSURES personnelles.
Please Note: For your protection, this product manual should be read and
thoroughly understood before unpacking, installing, using, or servicing the
described equipment.
UNIPOWER, LLC presents all equipment to the delivering carrier securely packed and
ready for transport. Upon acceptance of the equipment from us, the delivering carrier
assumes responsibility for its safe delivery to you. Once you receive the equipment, it is
your responsibility to document any damage to the equipment that was sustained during
transport to you and to file your claim with the carrier promptly and accurately.
PACKAGE INSPECTION
Before unpacking the shipment, examine the shipping container for any visible damage: punctures, dents, and any
other signs of possible internal damage.
Describe any damage or shortage on the receiving documents and have the carrier’s representative sign his/her
full name.
If the receiving freight bill notes that a Tip-N-Tell is attached to your freight, locate the indicator and note the
color of the arrow. If the Tip-N-Tell arrow has turned even partially blue, this means the freight has been tipped in
transport. Make sure the carrier notes this on your receipt before you sign for the freight.
EQUIPMENT INSPECTION
Promptly upon receipt of shipment, open the container and inspect the contents for damage; see the unpacking
section that follows. If it is necessary to move or otherwise handle the shipment, refer to the Handling section for
instructions and warnings.
Unpack the shipment carefully to avoid scratching or otherwise marring the exterior finish. Be careful not to
discard any included equipment, parts, or manuals. If damage is detected, call the delivering carrier to determine
appropriate action. The carrier may require an inspection.

ARE-S Series Chargers, Single Phase Front Matter
PM990.1090.XX, Rev. 10
ii
IMPORTANT: If damage is detected, save all shipping material for the carrier’s representative!
If damage is detected, also notify UNIPOWER, LLC; contact information is in Section 1.5 Product Support.
UNIPOWER, LLC will determine if the equipment should be returned for repair. If it is determined that the
equipment should be returned to UNIPOWER, LLC, ask the delivering carrier to send the packages back to
UNIPOWER, LLC at the delivering carrier's expense. Be sure that the equipment is properly packaged for
shipment.
If repair is necessary, UNIPOWER, LLC will invoice you for the repair so that you may submit the bill to the
delivering carrier with your claim form.
It is your responsibility to file a claim with the delivering carrier. Failure to properly file a claim for shipping
damages may void warranty service for any physical damages later reported for repair.
UNPACKING
A charger is shipped attached to a wood skid. This facilitates handling with a lift truck by inserting the forks
under the bottom of the skid. A smaller unit is covered by a carton and banded to a skid. A larger unit is bolted
to a skid and covered by a shipping carton that is banded to the skid.
Export packaging consists of a crate, a moisture-resistant cover for the charger, and a drying agent. The charger is
bolted to the crate.
To unpack:
CAUTION
Do not stand in front of steel bands since they may
whip out when cut.
ATTENTION
Ne pas se tenir devant les bandes d'acier, lorsque
coupées.
1. Cut the bands and remove carton from the skid.
2. Either remove the unit from the carton or unbolt the unit from the skid.
3. Check the shipping carton, before discarding, for the packing slip and other material, which may be
contained in it.
4. Carefully inspect the charger for shipping damage (i.e. loosened connections or mountings, dislodged
circuit boards). If damage is detected, notify UNIPOWER, LLC; contact information is provided in
Section 1.5 Product Support.
STORAGE
If the charger is not to be used immediately, store it (fully packed, if possible) in a clean, dry location protected
from physical damage, condensation, and overhead drip.

ARE-S Series Chargers, Single Phase Front Matter
PM990.1090.XX, Rev. 10
iii
HANDLING
Refer to the product nameplate for the model information and then see the Specifications section for charger
dimensions and weight. Use sufficient personnel and power equipment to ensure safe handling.
WARNING
Crush hazard
The charger can weigh up to 522 lbs (237 kg).
Keep hands and feet from beneath the charger.
Use a forklift or other equipment to move or transport
the charger.
AVERTISSEMENT
Risque d'écrasement
Le chargeur peut peser jusqu'à 522 lb (237 kg).
Gardez les mains et les pieds libres du dessous du
chargeur
Utilisez un chariot élévateur ou autres équipements pour
déplacer ou transporter le chargeur.
Use care in handling and unpacking the charger. Refer to the previous sections as needed.
NAMEPLATE
A UNIPOWER, LLC product is identified by a nameplate that includes model number, part number, and serial
number information, as appropriate. Please include this information in all correspondence with UNIPOWER,
LLC. A sample nameplate is shown below.
MODEL NO. ARE-S13025
SER.NO. APS1219980
AC VOLTS 120/208/240
PH 1 HZ 60
DC VOLTS 132
SPEC. 102.1090.13025
°T C 50
AC AMPS 48/28/24
CELLS 60
DC AMPS 25
TECHNICAL SUPPORT
CALL FIELD SERVICE
EMERGENCY
INITIAL SETTINGS
All equipment is shipped from the factory fully inspected and adjusted. Read the technical reference or product
manual before installing or making any adjustments.
SPARE PARTS
See the Parts Lists shown in the PN drawing that accompanies your charger to select the spare and replacement
parts you want immediately available to minimize downtime should a failure occur.

ARE-S Series Chargers, Single Phase Contents
PM990.1090.XX, Rev. 10
v
Table of Contents
1. INTRODUCTION ..............................................................................................................................................................1-1
1.1 PRODUCT DESCRIPTION................................................................................................................................... 1-1
1.2 MODEL DESIGNATION...................................................................................................................................... 1-2
1.2.1 Options................................................................................................................................................................1-2
1.3.1 Mechanical..........................................................................................................................................................1-2
1.3.2 Electrical.............................................................................................................................................................1-5
1.3.3 Front Panel Displays and Controls ....................................................................................................................1-7
1.3.4 Environmental.....................................................................................................................................................1-8
1.4 ABBREVIATIONS AND ACRONYMS ............................................................................................................... 1-9
1.5 PRODUCT SUPPORT......................................................................................................................................... 1-10
2. INSTALLATION................................................................................................................................................................2-1
2.1 INSTALLATION SUMMARY ............................................................................................................................. 2-1
2.2 REFERENCE MATERIAL.................................................................................................................................... 2-2
2.2.1 Tools and Accessories.........................................................................................................................................2-2
2.2.2 Selecting and Sizing DC Power Cables ..............................................................................................................2-2
2.3 MECHANICAL INSTALLATION ....................................................................................................................... 2-4
2.4 ELECTRICAL INSTALLATION.......................................................................................................................... 2-5
2.4.1 Grounding the Cabinet .......................................................................................................................................2-8
2.4.2 Installing a User’s AC Electrical Service Panel.................................................................................................2-8
2.4.3 Connecting AC Input Cables...............................................................................................................................2-8
2.4.4 Connecting the Battery String.............................................................................................................................2-9
2.4.5 Connecting an External DC Load.......................................................................................................................2-9
2.4.6 Connecting Alarm Annunciation.......................................................................................................................2-10
2.4.7 Connecting the Battery Temperature Probe (Option).......................................................................................2-12
3. COMMISSIONING............................................................................................................................................................3-1
3.1 PREPARATORY STEPS....................................................................................................................................... 3-1
3.2 COMMISSIONING PROCEDURE....................................................................................................................... 3-2
4. SETUP AND OPERATION...............................................................................................................................................4-1
4.1 TURNING ON ACOMMISSIONED CHARGER ................................................................................................ 4-1
4.2 TURNING OFF ACOMMISSIONED CHARGER............................................................................................... 4-1
4.3 SETTING UP AND OPERATING ACHARGER ................................................................................................. 4-1
4.3.1 The 4-Button Keypad ..........................................................................................................................................4-1
4.3.2 The Home Screen and Menus..............................................................................................................................4-2
4.3.3 View Active Alarms .............................................................................................................................................4-5
4.3.4 View Charger Status ...........................................................................................................................................4-5
4.3.5 Change Operating Mode (Manual Equalization) ...............................................................................................4-5
4.3.6 Alarm Relay/Lamp Test.......................................................................................................................................4-6
4.3.7 Change Charger Setup (Configuration)..............................................................................................................4-6
4.3.8 System Setpoints, System Alarms, and Summary Alarm .....................................................................................4-7
4.3.9 Guidelines ...........................................................................................................................................................4-7
4.3.9.1 Float and Equalize Voltages ........................................................................................................................................ 4-7
4.3.9.2 Low Voltage Alarm (LVA).......................................................................................................................................... 4-7
4.3.9.3 High Voltage Alarm (HVA) ........................................................................................................................................ 4-8
4.3.9.4 Primary (software) High Voltage Shutdown Voltage (HVSD)....................................................................................4-8
4.3.9.5 Secondary (hardware/software) High Voltage Shutdown (HVSD2)............................................................................4-8
4.3.9.6 Current Limit Alarm (CL)............................................................................................................................................ 4-8
4.3.9.7 Low Current (No Charge) Alarm (LCA/NCA) ............................................................................................................ 4-8
4.3.9.8 Rectifier Fail Alarm (RECTF) .....................................................................................................................................4-9
4.3.10 Set Parameter Values..........................................................................................................................................4-9
4.3.11 Battery Temperature Compensation ...................................................................................................................4-9
4.3.12 Auto-Equalize....................................................................................................................................................4-10
4.3.13 Load Share........................................................................................................................................................4-11
4.3.13.1 Field Connection and Setup of Load share ................................................................................................................ 4-11
4.3.13.2 Activating load share ................................................................................................................................................. 4-15
4.3.13.3 Operational Notes ...................................................................................................................................................... 4-15
4.3.14 Password...........................................................................................................................................................4-16
4.3.15 Factory Defaults ...............................................................................................................................................4-17

ARE-S Series 130V Chargers, Single Phase Contents
PM990.1090.XX, Rev. 10
vi
4.3.16 ARE-S user-programmable alarm relays functionality.....................................................................................4-18
4.3.17 User-programmable Alarm Relays Setup and Operation .................................................................................4-19
4.3.18 Factory Calibration ..........................................................................................................................................4-20
4.3.19 Field Calibrations.............................................................................................................................................4-20
5. CIRCUIT DESCRIPTION ................................................................................................................................................5-1
6. MAINTENANCE................................................................................................................................................................6-1
6.1 PREVENTIVE ....................................................................................................................................................... 6-1
6.2 TROUBLESHOOTING ......................................................................................................................................... 6-2
6.2.1 Service Access.....................................................................................................................................................6-2
6.2.2 Circuit Board Handling ......................................................................................................................................6-2
6.2.3 ARE-S LCD Display Codes.................................................................................................................................6-3
6.3 CHECKING COMPONENTS ............................................................................................................................... 6-8
6.4 INTERFACE BOARD (306.2991.48 OR 306.2991.130)........................................................................................ 6-9
6.4.1 Board Interchangeability ....................................................................................................................................6-9
6.4.2 Troubleshooting ..................................................................................................................................................6-9
6.4.3 Replacing the Interface Board ..........................................................................................................................6-10
6.5 CONTROL AND DISPLAY BOARD (306.2993.00).......................................................................................... 6-11
6.5.1 Replacing the Board .........................................................................................................................................6-11
6.6 CONTROL POWER SUPPLY BOARD (306.2990.48 OR 306.2990.130)........................................................... 6-12
6.6.1 Replacing the Board .........................................................................................................................................6-12
6.7 SCR TRIGGER BOARD (306.2989.00) .............................................................................................................. 6-13
6.7.1 Replacing the Board .........................................................................................................................................6-13
6.8 EXTENDED RELAY BOARD (306.2994.00) .................................................................................................... 6-14
6.8.1 Replacing the Board .........................................................................................................................................6-14
7. OPTIONS AND ACCESSORIES......................................................................................................................................7-1
7.1 LIGHTNING ARRESTER ............................................................................................................................................ 7-1
7.2 BLOCKING DIODE ................................................................................................................................................... 7-2
7.3 OUTPUT MOVS....................................................................................................................................................... 7-3
7.4 DRIP SHIELD ........................................................................................................................................................... 7-3
7.5 TEMPERATURE SENSOR........................................................................................................................................... 7-3
7.6 GROUND DETECTION SWITCH (STANDARD) ............................................................................................................ 7-3
7.7 REMOTE COMMUNICATIONS................................................................................................................................. 7-3
7.8 MEDIUM AND HIGH INTERRUPT AC BREAKERS...................................................................................................... 7-3
7.9 HIGH INTERRUPT DCBREAKERS (STANDARD ON 48V SYSTEMS)............................................................................. 7-3
List of Tables
TABLE 1-1 48V Model Designation........................................................................................................................................1-3
TABLE 1-2 130V Model Designation......................................................................................................................................1-4
TABLE 1-3 Cabinet Dimensions by Model ............................................................................................................................1-5
TABLE 1-4 General AC Voltage Range .................................................................................................................................1-5
TABLE 1-5 Model Specific and Related Specifications .........................................................................................................1-7
TABLE 1-6 Settable Parameters, Standard Models.................................................................................................................1-8
TABLE 2-1 Copper Wire Sizing .............................................................................................................................................2-3
TABLE 2-2 Torque Specifications, Steel Fasteners ................................................................................................................2-4
TABLE 2-3 Alarm State/Condition .......................................................................................................................................2-10
TABLE 4-1 Factory Default Setup Parameter Values.............................................................................................................4-7
TABLE 4-2 Typical Float/Equalize Voltages..........................................................................................................................4-8
TABLE 4-3 Default (Standard) Charger Settings..................................................................................................................4-18
TABLE 4-4 Custom Setup Menu Tree ..................................................................................................................................4-19
TABLE 6-1 Troubleshooting Chart .........................................................................................................................................6-5
TABLE 6-2 J4, Interface Board Jumper Settings ....................................................................................................................6-9

ARE-S Series Chargers, Single Phase Contents
PM990.1090.XX, Rev. 10
vii
List of Figures
FIGURE 2-1 ELECTRICAL INSTALLATION, BLOCK DIAGRAM ..................................................................................2-5
FIGURE 2-2 TYPICAL CHARGER ELECTRICAL ENTRANCE AND BREAKER LOCATIONS...................................2-6
FIGURE 2-3 ELECTRICAL INSTALLATION TERMINALS, 12" CABINET MODELS...................................................2-7
FIGURE 2-4 ELECTRICAL INSTALLATION TERMINALS, 17”, 24”, AND 30" CABINET MODELS..........................2-7
FIGURE 2-5 INTERFACE BOARD CONNECTIONS........................................................................................................2-11
FIGURE 2-6 RELAY BOARD ALARM CONNECTIONS .................................................................................................2-11
FIGURE 3-1 OPERATOR CONTROLS (FRONT VIEW TYP.) ...........................................................................................3-1
FIGURE 4-1 MAIN MENU ....................................................................................................................................................4-2
FIGURE 4-2 CHARGER STATUS MENU............................................................................................................................4-3
FIGURE 4-3 CHARGER OPERATING MODE MENU........................................................................................................4-3
FIGURE 4-4 CHARGER SETUP (CONFIGURATION) MENU ..........................................................................................4-4
FIGURE 4-5 ISSUE 1 CONTROL BOARD (NOT LOAD SHARE COMPATIBLE).........................................................4-12
FIGURE 4-6 ISSUE 1A BOARD (REQUIRES 306.2988.00 ISOLATOR BOARD) ..........................................................4-12
FIGURE 4-7 ISSUE 2, 2A OR LATER BOARD (LOAD SHARE READY) .......................................................................4-12
FIGURE 4-8 2-CHARGER LOAD SHARE SETUP EXAMPLE ........................................................................................4-13
FIGURE 4-9 3-CHARGER LOAD SHARE SETUP EXAMPLE ........................................................................................4-13
FIGURE 4-10 EOL (END OF LINE) JUMPER (ISSUE 2A BOARD SHOWN)..................................................................4-14
FIGURE 4-11 LOAD SHARE CONFIGURATION MENU SCREENS...............................................................................4-15
FIGURE 4-12 HOME SCREEN DURING ACTIVE LOADSHARING ...............................................................................4-15
FIGURE 4-13 EXTENDED RELAY BOARD ......................................................................................................................4-18
FIGURE 4-14 FRONT PANEL CUSTOM LEDS .................................................................................................................4-19
FIGURE 4-15 DIGITAL INPUTS..........................................................................................................................................4-20
FIGURE 5-1 BLOCK DIAGRAM, TYPICAL ARE-S FLOAT CHARGER .........................................................................5-1
FIGURE 6-1 INTERFACE BOARD CONNECTIONS........................................................................................................6-10
FIGURE 6-2 CONTROL AND DISPLAY BOARD.............................................................................................................6-11
FIGURE 6-3 CONTROL POWER SUPPLY BOARD .........................................................................................................6-12
FIGURE 6-4 SCR TRIGGER BOARD .................................................................................................................................6-13
FIGURE 6-5 EXTENDED RELAY BOARD .......................................................................................................................6-14
FIGURE 7-1 LIGHTNING ARRESTER; 120, 208, 240 AND 480 VAC CONNECTIONS..................................................7-1
FIGURE 7-2 BLOCKING DIODE..........................................................................................................................................7-2

ARE-S Series Chargers, Single Phase Introduction
PM990.1090.XX, Rev. 10
1-1
1. INTRODUCTION
The purpose of this manual is to provide the reader with the procedures for installing, configuring, operating, and
servicing UNIPOWER ARE-S Chargers. Both 48V and 130V models are covered by this manual.
Chapter 1 Introduction provides a description of the ARE-S series chargers, the model designation list, and
detailed specifications. This chapter also has product support telephone and FAX numbers and the company’s
Internet URL where the latest issue of this manual can be found.
Chapter 2 Installation describes mechanical and electrical installation of the charger. Each aspect of the
installation is discussed and supporting illustrations are provided.
Chapter 3 Commissioning presents a suggested procedure that can be integrated into or modified by your
company’s commissioning procedures.
Chapter 4 Setup and Operation describes charger displays and use of the 4-button keypad. Setup menus are
provided to ease navigation through the provided displays. Default setup values are listed.
Chapter 5 Circuit Description includes a block diagram level description of the charger circuitry. Read this
chapter before installing, configuring, operating, or servicing the charger.
Chapter 6 Maintenance provides preventive maintenance and troubleshooting information. A troubleshooting
chart is included. Troubleshooting information for internal circuit boards is included in this section as well.
Chapter 7 Options and Accessories furnishes details concerning the accessories available at the time this manual
was published.
1.1 PRODUCT DESCRIPTION
The ARE-S Series of single-phase, controlled SCR float chargers is intended for utility, communications, and
other applications where a source of stable, electrically clean, reliable DC power is needed. Available models
provide a nominal output voltage of 48 Vdc or 130 Vdc and an output current from 6-75 amperes, depending
upon model. Refer to section 1.2 for a list of standard models and options.
Installation is quick and easy. The design accommodates floor, wall, or rack mounting with standard and optional
brackets. A mounting method is usually specified on the equipment order so the proper brackets can be supplied
with the initial shipment.
The charger is configured and operated from the front of the unit. The control section includes a 2-line digital
display, 4-button keypad, green/red STATUS/ALARM LED, an AC input circuit breaker, a DC output circuit
breaker and LED indicators showing the status of the AC Fail alarm, High Voltage Shutdown and High Voltage
alarm, Low Voltage and Very Low Voltage alarm, Equalize mode, Low Current alarm, Positive Ground Fault
alarm, and Negative Ground Fault alarm, and High Battery Temperature alarm. A Ground Detection Enable
switch is also included standard on all models.
Access to internal components for servicing by qualified personnel is through the door comprising the front of the
unit. The door is hinged on the left and secured on the right by two ¼-turn fasteners.

ARE-S Series Chargers, Single Phase Introduction
PM990.1090.XX, Rev. 10
1-2
1.2 MODEL DESIGNATION
The nameplate on the charger contains an alphanumeric model number. The model number describes the features
built into a particular charger. Table 1-1 provides the product characteristic defined by each character in the model
number.
1.2.1 Options
Higher Interrupt AC Breakers ........... 22K AIC minimum
Lightning Arrester ............................. AC input; prevents equipment damage due to a nearby lightning strike
High Interrupt DC Breakers .............. 42K AIC minimum (130V chargers)
MOVs ................................................ On DC output, prevents equipment damage due to excessive voltage
transients
Blocking Diode.................................. Prevents charger faults from shorting the battery plant
Eliminator Filtering ........................... Provide lower ripple for load and operation with batteries disconnected.
Temperature Compensation............... Slopes adjusted from –0.1mV/cell/C to –10.0mv/cell/C
SIS Control Wiring............................ Excludes CAT5e communication cables and power cables
Alarm Relays..................................... Provided contacts to indicate individual alarm conditions
Remote Communications .................. Future option
Drip Shield ........................................ Prevents overhead drops from entering unit
Engraved Nameplates........................ Contact UNIPOWER Applications Engineering
Fungicide Treatment.......................... Applied to inside of charger, contact UNIPOWER Applications Engineering
1.3 SPECIFICATIONS
This section provides the mechanical, electrical, and environmental specifications. The charger nameplate is
located on the front panel.
1.3.1 Mechanical
Cabinet.................................................... NEMA1; steel with baked powder coat finish
Cable Entrances...................................... Three (3); see the dimension drawings on the PN drawing specific to the
charger model ordered (supplied)
Cabinet Dimension and Weight.............. See Table 1-3 and dimension drawings in Chapter 2 Installation.
Mounting Locations................................ Wall, relay rack, or floor
Select a location for the charger. The chargers are cooled by natural convection and require at least 3" (76mm) of
space below the charger and 3" above the charger.
Mounting Brackets
Supplied............................................. Wall mount and standard relay rack mount
Optional............................................. Larger relay rack mount or floor mount
Internal Combustible Materials .............. 94V-1 or better