Instructions

EN
UB20.241 Installation Manual
Product Description
The UB20.241 is an uninterruptible power supply controller (DC-UPS), which is used in combination
with a 24V power supply and one external 24V-battery to bridge power failures. When the power
supply provides sufficient voltages, the DC-UPS controller charges the battery. When the power
supply voltage fails, the energy stored in the battery is released to the DC bus in a regulated process.
Intended Use
This device is designed for installation in an enclosure and is intended for commercial use, such as in
industrial control, process control, monitoring and measurement equipment or the like. Do not use this
device in equipment where malfunction may cause severe personal injury or threaten human life.
Installation Instructions
Turn power off and disconnect the battery fuse before working on the device.
Install the device in an enclosure providing protection against electrical, mechanical and fire hazards.
Install the device onto a DIN-rail according to EN 60715 with the input terminals on the top of the unit.
The input can be powered from a regulated power supply or a similar DC source. The voltage between
the input and ground must not exceed 60Vdc continuously. The ripple voltage in the low frequency
range between 50Hz and 10kHz must be negligible when used in marine applications.
The input must be powered from a PELV or SELV source or an “Isolated Secondary Circuit” in order to
maintain a SELV or PELV output.
Use an appropriately sized 24V power supply, which can deliver the additional internal current
consumption, required to charge the battery.
Use only VRLA lead acid batteries with a capacity between 3.9Ah and 150Ah.
Check for correct input and battery polarity. The device will not operate when the voltage is reversed.
Make sure that the wiring is correct by following all local and national codes. Use appropriate copper
cables that are designed for a minimum operating temperature of 60°C for ambient temperatures up to
+45°C, 75°C for ambient temperatures up to +60°C and 90°C for ambient temperatures up to +70°C.
Ensure that all strands of a stranded wire enter the terminal connection.
Do not use wires smaller than 4mm
2
(AWG 12) and not longer than 2x1.5m between the battery and
the DC-UPS controller. Longer or smaller gauge wires can change performance of the system.
Use a 35A fuse (ATOF
®
287 035 from Littelfuse or an UL listed fuse with the same characteristics) in
the battery circuit. The battery fuse protects the wires between the battery and the DC-UPS and shall
be located close to the battery.
The device is designed for pollution degree 2 areas in controlled environments.
No condensation or
frost is allowed.
The device is designed as “Class of Protection III” equipment according to IEC 61140.
The enclosure of the device provides a degree of protection of IP20.
A disconnecting means shall be provided for the input and the battery input of the device.
The device is designed for convection cooling and does not require an external fan. Do not obstruct
airflow and do not cover ventilation grid!
Keep the following minimum installation clearances: 40mm on top, 20mm on the bottom, 5mm left and
right side. Increase the 5mm to 15mm in case the adjacent device is a heat source. When the device
is permanently loaded with less than 50%, the 5mm can be reduced to zero.
The device is designed for altitudes up to 6000m (19685ft). See additional requirements in the product
datasheet for use above 2000m (6560ft)
The maximum surrounding air temperature is +70°C (+158°F). The operational temperature is the
same as the ambient or surrounding air temperature and is defined 2cm below the device.
The device is designed to operate in areas between 5% and 95% relative humidity.
The device is designed, tested and approved for branch circuits up to 28A without additional protection
device.
Use a 25A melting fuse with a melting I
2
t of 400A
2
s – 1500A
2
s or a 25A circuit breaker with tripping
characteristic B, C, D or K on the input of the DC-UPS if the current of the power supply is higher than
28A.
Use a 4A fuse (ATOF
®
287 004 from Littelfuse or an UL listed fuse with same characteristics) between
the connection point of the two 12V batteries and the “Center Tap” connection point of the DC-UPS.
An equivalent protection is included on the original battery modules. The center tap connection is not
mandatory but enables an individual charging and monitoring of the two batteries.
Optionally, a PT1000 temperature sensor can be connected to terminals point 11 and 12 to measure
the battery temperature. This adjusts the charging voltage according to the battery temperature which
extends the battery life. This sensor is already installed in the original battery modules.
Installation Instructions for Hazardous Location Areas
The device is suitable for use in Class I Division 2 Groups A, B, C, D locations and for use in Group II
Category 3 (Zone 2) environments.
Hazardous Location Classification: ATEX: EPS 15 ATEX 1 025 X, II 3G EX ec nC IIC T4 Gc
WARNING EXPLOSION HAZARDS!
Substitution of components may impair suitability for this environment.
Do not disconnect the device or change unit settings unless power has been switched off or the area
is known to be non-hazardous.
A suitable enclosure must be provided for the end product which has a minimum protection of IP54
and fulfils the requirements of the EN 60079-0.
Technical Data
All values are typical figures specified at 24Vdc input voltage, 20A output
current in power supply mode at 25°C ambient, no charging and after a 5
minutes run-in time unless otherwise noted.
Input voltage DC 24V ±25%
Minimum input voltage to
start charging and to
enable battery mode
Adjusted transfer voltage to switch into
battery mode.
Transfer voltage to switch
into battery mode
23.5V, 25.0V,
26.0V, 27.0V
Depending on the
selected buffer voltage
Internal current
consumption
2.1A / 4.0A <10Ah / >10Ah, Includes
charging current
Output in power supply mode:
Input to output voltage loss 70mV At 10A output load
135mV At 20A output load
Output current 25A Below +60°C
18.8A At +70°C
30A Short term, up to 5s
Derate linearely between +60°C and +70°C
Output in battery mode:
Output voltage 22.5V, 24.0V,
25.0V, 26.0V
Depending on the
selected buffer voltage
Output current 20A At 22.5V, below +60°C
15A At 22.5V and +70°C
30A Short term, up to 4s
Derate linearely between +60°C and +70°C
Power losses 4.6W At 20A output load
Temperature range -40°C to +70°C
Max. wire size (litz wire) 4mm² For power terminals
Wire size AWG AWG 20-10 For power terminals
Max. wire diameter 2.8mm For power terminals
Wire stripping length 7mm/ 0.28inch For power terminals
Tightening torque 1Nm/ 9lb.inch For power terminals
Max. wire size (litz wire) 1.5mm² For signal terminals
Wire size AWG AWG 22-14 For signal terminals
Max. wire diameter 1.5mm For signal terminals
Wire stripping length 6mm/ 0.25inch For signal terminals
Tightening torque 0.4Nm/ 3.5lb.inch For signal terminals
Size (wxhxd) 46x124x127mm Without DIN-rail
Weight 700g / 1.54lb
Functional Diagram
Battery Size
Selector
-
+
-
+
Buck/Boost
Converter
Battery
Charger
2
Current
Limiter
Battery
Tester 1
+
-
Input Output
24V
Battery
Diagnosis LED
Status LED Batt 1
Inhibit Input +
Controller
Error LED
Replace Battery
Buffering Contact
Ready Contact
Buffer-time Limiter
Buffer Voltage
(7)
Inhibit Input -
(8)
(1)
(2)
(3)
(4)
(5)
(6)
Return Current
Protection
Battery
Charger
1
Battery
Tester 2
Current
Measurement
Status LED Batt 2
(11)
(12)
Temp.
Sensor
(13)
Center
Tap
24V
Battery
Wiring Scheme
Battery
Temp. Sensor
OutputInput
Fuse
+-
BAT1
12V
+-
BAT2
12V
(+)
(-)
Temp.
Sensor
Center-Tap
Temp.
Sensor
Auto
Resettable
Fuse
PT1000
Center-Tap
(13)
(12)
(11)
DC-UPS
Load
Power
Supply
Output
Input
o
+
-
+
-
o
o
+
-
24V Battery Module
+
-
+
-
L N
PE