Reference Manual Owner manual

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Reference Manual

General Description ............................................1

2. Specication Quick Reference .............................1

3. Catalog Numbers .....................................................1

4. Certication Marks

...................................................1

5. Input ............................................................................3

6. Output in Normal Mode

........................................4

7. Output in Buer Mode

............................................5

8. Battery Input

..............................................................7

9. Buer Time ...............................................................8

10. Eciency and Power Losses ...............................10

11. Functional Diagram ...........................................10

12. Check Wiring and Battery Quality Tests

..........11

13. Relay Contacts and Inhibit Input .....................12

14. Front Side User Elements ....................................13

15. Terminals and Wiring

...........................................14

16. Reliability .......................................................... 15

17. EMC ...................................................................... 16

18. Environment ................................................... 17

19. Protection Features .................................... 17

20. Safety .................................................................. 18

21. Certications ..................................................... 18

22. Environmental Compliance ......................... 19

23. Physical Dimensions and Weight

.............. 19

24. Installation Notes ......................................... 20

25 Accessories ........................................................ 21

26. Application Notes ......................................... 22

26.1. Battery Replacement Intervals

...... 22

26.2. Parallel and Serial Use

....................... 23

26.3. Using the Inhibit Input ..................... 24

26.4. Troubleshooting

................................. 24

Bulletin 1606 Switched Mode Power Supplies

Catalog Number: 1606-XLS240-UPSD

Index

•DC UPS—Uninterruptible power supply with DC input.

•Normal mode—Describes a condition where the battery is charged, the input voltage is in range and the output is loaded within the

allowed limits..

• Buffer mode—Describes a condition where the input voltage is below the transfer threshold level, the unit is running on battery (buffering)

and the output is loaded within the allowed limits.

• Charging mode—Describes a condition where the battery is being charged, the input voltage is in range and the output is loaded within the

allowed limits.

• Inhibit mode—Describes a condition where buffering is disabled intentionally by using the inhibit input of the DC UPS (e.g. for service

actions or to save battery capacity).

•Buffer time—Equivalent to the term “hold-up time.”

• T.b.d.—To be defined, value or description will follow later.

Terminology and Abbreviations

Summary of content (28 pages)

PAGE 1
Reference Manual Bulletin 1606 Switched Mode Power Supplies Catalog Number: 1606-XLS240-UPSD Index 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. General Description ............................................1 Specification Quick Reference .............................1 Catalog Numbers .....................................................1 Certification Marks ...................................................1 Input ............................................................................
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Bulletin 1606 Switched Mode Power Supplies DC-UPS, Dual Output ■ ■ ■ ■ ■ ■ ■ ■ ■ 24V DC-UPS With an Additional 12V Output for Various Applications Only One 12V Battery Required Stable Output Voltage in Buffer Mode Superior Battery Management for Longest Battery Life Comprehensive Diagnostic and Monitoring Functions Replace Battery Signal Included Electronically Overload and Short Circuit Protected 50% Power Reserves 3 Year Warranty 1. Description 2.
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Bulletin 1606 Switched Mode Power Supplies Intended Use • This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office, communication, and instrumentation equipment. • Do not use this power supply in aircraft, trains, nuclear equipment or similar systems where malfunction may cause severe personal injury or threaten human life.
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Bulletin 1606 Switched Mode Power Supplies 5. Input nom. nom. Input voltage Input voltage ranges DC 24V 22.5 to 30Vdc 30 to 35Vdc 35Vdc 0 to 22.5Vdc Allowed input voltage ripple max. Allowed voltage between input and earth (ground) Turn-on voltage max. Input current **) typ. 1.5Vpp 1Vpp 60Vdc or 42.4Vac 22.8Vdc max. typ. typ. 23Vdc 140mA 1.1A External capacitors on the input Continuous operation, see Fig.
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Bulletin 1606 Switched Mode Power Supplies 6. Output in Normal Mode The total output power of 360W can be shifted dynamically between the two outputs. 24V Output: Output voltage Voltage drop between input and output Ripple and noise voltage Output current Short-circuit current nom. DC 24V max. max. max. nom. min. min. max. 0.3V 0.45V 20mVpp 0 – 15A 12.3A 17.9A 21A No limitation nom.
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Bulletin 1606 Switched Mode Power Supplies 7. Output in Buffer Mode If the input voltage falls below the transfer threshold level, the DC-UPS starts buffering without any interruption or voltage dips. The transfer threshold level is typically 80mV higher than the 24V output voltage in buffer mode. Buffering is possible even if the battery is not fully charged. 24V Output Output voltage nom. Ripple and noise voltage Output current max. nom. Short-circuit current min. min. max.
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Bulletin 1606 Switched Mode Power Supplies Fig. 7-3 Available output current in buffer mode Fig. 7-4 24V Output voltage vs. output current in buffer mode, typ. Output Voltage Output Current 25V A B 20 BonusPower 15A 15 D 10 10A C 5 Output Current 0 5A 5 0 Time 0 0 5 Sec. A B C D 10 15 20 Continuously available Available for 5s then auto switching to curve Buffering will stop after 5s Buffering will stop after 5s 25A D Fig. 7-5 12V Output voltage vs.
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Bulletin 1606 Switched Mode Power Supplies 8. Battery Input The DC-UPS requires one 12V VRLA battery to buffer the 24V and 12V output. Battery voltage nom. Battery voltage range max. typ. min. max. max. Allowed battery sizes Internal battery resistance Battery charging method Battery charging current (CC-mode) nom. max. End-of-charge-voltage (CV-mode) Battery charging time typ. typ. typ. Battery discharging current **) Deep discharge protection ***) DC 12V 9.0 – 15.0V 35Vdc 7.4V 3.
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Bulletin 1606 Switched Mode Power Supplies 9. Buffer Time The buffer time depends on the capacity and performance of the battery as well as the load current. The diagram below shows the typical buffer times of the 24V output with the standard battery modules at 20°C. Buffer time with battery module 1606-XLSBATASSY1 min. min. typ. typ. Buffer time with battery module 1606-XLSBATASSY2 min. min. typ. typ.
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Bulletin 1606 Switched Mode Power Supplies event, the process is completed much faster since only the energy which was taken out of the battery needs to be “refilled”. For this reason, the buffer time cannot be calculated using the Ah capacity value. The equation “I x t” = capacity in Ah generally leads to incorrect results when the discharging current is higher than C20 (discharging current for 20h).
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Bulletin 1606 Switched Mode Power Supplies 10. Efficiency and Power Losses Efficiency typ. typ. typ. typ. typ. typ. typ. typ. Power losses 97.5% 96% 3.4W 6W 10W 5.5W 19W 23W Normal mode, 24V 10A, 12V 0A, battery fully charged Normal mode, 24V 7.0A, 12V 5A, battery fully charged Normal mode, no load, battery fully charged Normal mode, 24V 10A , 12V 0A, battery fully charged Normal mode, 24V 12.3A, 12V 5A, battery fully charged During battery charging, no load.
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Bulletin 1606 Switched Mode Power Supplies 12. Check Wiring and Battery Quality Tests The DC-UPS is equipped with an automatic “ Check Wiring” and “Battery Quality” test. “Check Wiring” test: Under normal circumstances, an incorrect or bad connection from the battery to the DC-UPS or a missing (or blown) battery fuse would not be recognized by the UPS when operating in normal mode. Only when backup is required would the unit be unable to buffer. Therefore, a “check wiring” test is included in the DC-UPS.
PAGE 13
Bulletin 1606 Switched Mode Power Supplies 13. Relay Contacts and Inhibit Input The DC-UPS is equipped with relay contacts and signal inputs for remote monitoring and control of the unit. Relay contacts: Ready: Buffering: Replace Battery: Contact is closed when battery is charged more than 85%, no wiring failure is recognized, input voltage is sufficient and inhibit signal is inactive. Contact is closed when unit is buffering.
PAGE 14
Bulletin 1606 Switched Mode Power Supplies 14. Front Side User Elements A Power Port Quick-connect spring-clamp terminals, connection for input voltage, output voltage and battery. The 12V power port is placed on the bottom. B Signal Port Plug connector with screw terminals, inserted from the bottom. Connections for the Ready, Buffering, Replace Battery relay contacts and for the Inhibit input. See details in section 13.
PAGE 15
Bulletin 1606 Switched Mode Power Supplies 15. Terminals and Wiring Power terminals (except 12V) 12V Terminal Signal terminals Type Bi-stable, quick-connect spring-clamp terminals. Shipped in open position. Lockable plug connector with spring-clamp terminals. Solid wire Stranded wire AWG Ferrules Pull-out force 0.5-6mm2 0.1-2.5mm2 2 0.5-4mm 0.1-2.
PAGE 16
Bulletin 1606 Switched Mode Power Supplies 16. Reliability Lifetime expectancy, normal mode MTBF SN 29500, IEC 61709, normal mode MTBF MIL HDBK 217F, normal mode min. min. min.
PAGE 17
Bulletin 1606 Switched Mode Power Supplies 17. EMC The unit is suitable for applications in industrial environmental as well as in residential, commercial and light industry. environment without any restrictions. The CE Mark is in conformance with EMC directive 89/336/EC and 93/68/EC & 2004/108/EC and the low-voltage directive (LVD) 73/23/EC, 93/68/EC, 2006/95/EC. A detailed EMC Report is available on request.
PAGE 18
Bulletin 1606 Switched Mode Power Supplies 18. Environment Operational temperature -25°C to +70°C (-13°F to 158°F) Derating 6W/°C Storage temperature -40 to +85°C (-40°F to 185°F) Humidity 5 to 95% r.H. Vibration, sinusoidal Shock Altitude Over-voltage category 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g 30g 6ms, 20g 11ms 0 to 6000m III II 2 Degree of pollution For the DC-UPS control unit. Keep battery in a cooler environment! at +50°C to +70°C (122°F to 158°F), normal mode see Fig.
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Bulletin 1606 Switched Mode Power Supplies 20. Safety Output voltage Class of protection Isolation resistance Dielectric strength Touch current (leakage current) SELV IEC/EN 60950-1 PELV EN 60204-1, EN 50178, IEC 60364-4-41 Max. allowed voltage between any input, output or signal pin and ground: 60Vdc or 42.
PAGE 20
Bulletin 1606 Switched Mode Power Supplies 22. Environmental Compliance The unit does not release any silicone and is suitable for use in paint shops. The unit conforms to the RoHS directive 2002/96/EC. Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems. Plastic housings and other molded plastic materials are free of halogens.
PAGE 21
Bulletin 1606 Switched Mode Power Supplies 24. Installation Notes Mounting: The power terminal must be located on top of the unit. An appropriate electrical and fire end-product enclosure should be considered in the end-use application. Cooling: Convection cooled, no forced air cooling required. Do not obstruct air flow! Installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently with full power.
PAGE 22
Bulletin 1606 Switched Mode Power Supplies 25. Accessories Battery Modules Two pre-assembled battery modules with a single 12V battery are available for different buffer times. As an option, the mounting brackets are also available without batteries. This option offers more flexibility in selecting an appropriate battery, which can also save on shipping expenses. See individual datasheets for detailed information.
PAGE 23
Bulletin 1606 Switched Mode Power Supplies 26. Application Notes 26.1. Battery Replacement Intervals Batteries have a limited life time. They degrade slowly beginning from the production and need to be replaced periodically. The design life figures can be found in the individual datasheets of the batteries and are usually specified according to the Eurobat guideline or according to specifications from the manufacturer.
PAGE 24
Bulletin 1606 Switched Mode Power Supplies Example for calculating the service life and the required replacement cycle: Parameters for the example: A 7Ah battery with a design life of 3-5 years is used (e.g. Yuasa battery from the 1606-XLSBATASSY1 battery module). The average ambient temperature is 30°C One buffer event consumes approx. 25% of the achievable buffer time. One buffer event per day Calculation: Ambient temperature influence: According to Fig.
PAGE 25
Bulletin 1606 Switched Mode Power Supplies 26.3. Using the Inhibit Input The inhibit input disables buffering. In normal mode, a static signal is required. In buffer mode, a pulse with a minimum length of 250ms is required to stop buffering. The inhibit is stored and can be reset by cycling the input voltage. For service purposes, the inhibit input can also be used to connect a service switch. Therefore, the inhibit signal can be supplied from the output of the DC-UPS. Fig.
PAGE 26
Bulletin 1606 Switched Mode Power Supplies 26 All parameters are specified at an input voltage of 24V, 10A output load, 25°C ambient and after a 5 minutes run-in time unless noted otherwise. It is assumed that the input power source can deliver a sufficient output current.
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