Datasheet UB10.241 Datasheet (PULS)

Page 1

1. GENERAL DESCRIPTION

This uninterruptible power supply (UPS) controller UB10.241 is an addition to standard 24V power supplies to bridge power failures or voltage fluctuations. Expensive downtimes, long restart cycles and loss of data can be avoided.

The DC-UPS includes a professional battery managem the battery to achieve the longest battery service life as well as many diagnostic functions that ensure a reliable operation of the entire system.

A unique feature of the UB10.241 is that only one 1

2V battery is required to buffer the 24V output. This makes matching batteries unnecessary and allows a precise battery charging and testing.

The UB10.241 requires one exte which two preassembled battery modules are available. A lightweight 7Ah battery which can be mounted on the DIN-Rail and a 26Ah module that can be panel mounted for longer buffer times.

In addition to the UB10.241, the UBC10.241 UPS inc

ludes the same controller with an integrated 5Ah

battery.

ent system which charges and monitors

rnal 12V battery for

UB10.241

DC-UPS CONTROL UNIT

■ Requires Only One 12V Battery for a 24V Output

■ 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

■ Selectable Buffer Time Limiter

■ 3 Year Warranty

2. SHORT-FORM DATA

Input voltage nom. 24Vdc range 22.5-30Vdc Output current min.15A Normal mode min. 10A Buffer mode Output voltage typ. 0.23V lower

s input voltage

22.25V Buffer mode, 10A Allowed batteries 3.9Ah to 40Ah VRLA lead acid Temperature range -25 to +70°C Operational

Derating 0.43A/°C

Dimensions 49x124x117mm WxHxD Buffer time (at 10A) typ. 6’45” 7Ah battery module typ. 55’ 26Ah batt. module

Typical setup of a DC-UPS system with the UB10.241:

24V Power Supply

e.g.:

Dimension

24V

DC-UPS

UB10.241

12V

Battery

e.g.: UZK12.xxx

Normal mode

+60°C to +70°C

l mode

norma

24V

Load

e.g.: PLC

3. ORDER NUMBERS

DC-UPS

Accessories UZK12.071 UZO12.07

UB10.241

UZK12.261 UZO12.26

ZM1.WALL

Standard controller

Battery module 12V 7Ah Mounting kit w/o battery

Battery module 12V 26Ah Mounting kit w/o battery

Panel/Wall mount bracket

4. MARKINGS

IND. CONT. E

UL 508

EMC, LVD

UL 60950-1

Marine

Class I Div 2

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UB10.241

INDEX PAGE INDEX PAGE

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

2. Short-form Data ..................................................1

3. Order Numbers ....................................................1

4. Markings ..............................................................1

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

6. Output in Normal Mode .....................................4

7. Output in Buffer Mode .......................................5

8. Battery Input .......................................................6

9. Buffer Time..........................................................7

10. Efficiency and Power Losses................................9

11. Functional Diagram.............................................9

12. Check Wiring and Battery Quality Tests...........10

13. Relay Contacts and Inhibit Input......................11

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

15. Terminals and Wiring........................................14

16. Reliability...........................................................14

17. EMC ................................................................... 15

18. Environment ..................................................... 16

19. Protection Features .......................................... 16

20. Safety ................................................................ 17

21. Approvals.......................................................... 17

22. Fulfilled Standards............................................ 17

23. Used Substances ............................................... 18

24. Physical Dimensions and Weight..................... 18

25. Installation Notes ............................................. 19

26. Accessories ........................................................ 20

27. Application Notes............................................. 21

27.1. Battery Replacement Intervals............... 21

27.2. Parallel and Serial Use............................ 22

27.3. Using the Inhibit Input........................... 23

27.4. Troubleshooting..................................... 23

INTENDED USE

The unit shall only be installed and put into operation by qualified personnel. This unit is designed for installation in an enc

office, communication, and instrumentation equipment. Do not use this device in aircraft, trains and nuclear equipment, where malfunctioning of the power supply may cause severe personal injury or threaten human life.

losure and is intended for general use, such as in industrial control,

TERMINOLOGY AND ABREVIATIONS

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 De

Buffer time Same a

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

scribes a condition where buffering is disabled on purpose by using the inhibit input of the DC-

UPS. (e.g. for service actions, or to save battery capacity)

s the term “hold-up time”.

DISCLAIMER

The information presented in this document is believed to be accurate and reliable and may change without notice. Some parts of this unit are patent by PULS (US patent No 091662,063, Des. 424,529, …).

No part of this document may be reproduced or utilized in any form without permission in writing from the publisher.

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UB10.241

5. INPUT

Input voltage nom. DC 24V Input voltage ranges nom. 22.5 to 30Vdc Continuous operation, see Fig. 5-1 30 to 35Vdc Temporarily allowed, no damage to the DC-UPS *)

Allowed input voltage ripple max. 1.5Vpp Bandwidth <400Hz 1Vpp Bandwidth 400Hz to 1kHz

Allowed voltage between input and earth (ground)

Turn-on voltage

max. 23Vdc Input current **) typ. 120mA Internal current consumption typ. 1.1A Current consumption for battery charging in constant

External capacitors on the input

*) The DC-UPS shows “Check Wiring” with the red LED and buffering is not possible **) The total input current is the sum of the output current, th

charging process and the current which is needed to supply the DC-UPS itself. See also Fig. 5-2. This calculation does not apply in overloa

***) Please note: This is the input current and not the current which flows into the battery during charging. The battery current ca

be found in chapter

d situations where the DC-UPS limits the output current, therefore see

Fig. 5-1 Input voltage range Fig. 5-2 Input current, definitions

OUT

35Vdc Absolute maximum input voltage with no damage to the

DC-UPS

0 to 22.5Vdc The DC-UPS switches into buffer mode and delivers

output voltage from the battery if the input was above the turn-on level before and all other buffer conditions are fulfilled.

max. 60Vdc or

42.4Vac

typ. 22.8Vdc The output does not switch on if the input voltage does

not exceed this level.

current mode at 24V input See Fig. 8-2 ***)

No limitation

e current which is required to charge the battery during the

Fig. 5-3.

Input

Current

Output Current

18 30 35V22.50

A: Rated input voltage range B: Temp. allowed, no harm to the unit C: Absolute max. input voltage D: Buffer mode

Electronic output current limitation

The DC-UPS is equipped with an electronic output current limitation. This current limitation works in a switching mode which reduces the power losses and heat generation to a minimum. As a result, the output voltage drops since there is not enough current to support the load. A positive effect of the current limitation in switching mode is that the input current goes down despite an increase in the output current resulting in less stress for the supplying source.

consumptio n

for battery

charging

Current

Internal current

consumptio n

Fig. 5-3 Input current and output voltage vs.

output current, typ. (battery fully charged)

20V

20A

Output Voltage

4812 20A

Overload

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UB10.241

6. OUTPUT IN NORMAL MODE

Output voltage in normal mode

output max. 0.45V At 15A output current, see Fig. 6-1 for typical values Ripple and noise voltage max. 20mVpp 20Hz to 20MHz, 50Ohm *) Output current nom. 15A Continuously allowed Output power nom. 360W Continuously allowed Short-circuit current min. 17.9A Load impedance 100mOhm, see Fig. 6-2 for typical values max. 21A Load impedance 100mOhm, see Fig. 6-2 for typical values Capacitive and inductive loads No limitation

*) This figure shows the ripple and noise voltage which is generated by the DC-UPS. The ripple and noise voltage

might be higher if the supplying source has a higher ripple and noise voltage.

Fig. 6-1

Input to Output Voltage drop

0.4V

0.35

0.25

0.15

0.05

Input to output voltage drop, typ.

0.3

0.2

0.1

02 10

4 6 8 12 14 16

nom. DC 24V The output voltage follows the input voltage reduced by

the input to output voltage drop.

max. 0.3V At 10A output current, see Fig. 6-1 for typical values Voltage drop between input and

Fig. 6-2 Output voltage vs. output current in

normal mode at 24V input, typ.

Output Voltage

28V

18A

4 0

0 5 10 15 20

Output Current

25A

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UB10.241

7. OUTPUT IN BUFFER MODE

If the input voltage falls below a certain value (transfer threshold level), the DC-UPS starts buffering without any

interruption or voltage dips. Buffering is possible even if the battery is not fully charged.

Output voltage in buffer mode

Ripple and noise voltage max. 20mVpp 20Hz to 20MHz, 50Ohm Output current nom. 10A Continuously allowed 15A < 5s with full output voltage *) Short-circuit current min. 17.9A Load impedance 100mOhm **) max. 21A Load impedance 100mOhm **)

*) If the output current is in the range between 10A and 15A for longer than 5s, a hardware controlled reduction of the

maximal output current to 10A occurs. If the 10A are not sufficient to maintain the 24V, buffering stops after another 5s. The buffering is possible again as soon as the input voltage recovers.

**) If the nominal output voltage cannot be maintained in buffer mode,

capacity.

Fig. 7-1 Buffering transition, definitions Fig. 7-2 Transfer behavior, typ.

nom. DC 24V Output voltage is stabilized and independent from

battery voltage

22.45V ±1%, at no load,

22.25V ±1%, at 10A output current typ. 80mV higher than the output voltage in buffer mode Transfer threshold for buffering

the DC-UPS switches off after 5s to save battery

Input voltage

28V 24V

Transfer

threshold

Output voltage

Buffer mode

Fig. 7-3

Available output current in buffer

Output Current

mode

15A

10A

05 Sec.

BonusPower

Time

Fig. 7-4 Output voltage vs. output current in

Output Voltage

25V

20 15

Continuously available

Available for 5s then auto switching to curve

Buffering will stop after 5s

buffer mode, typ.

A B

Output Current

5101520

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UB10.241

8. BATTERY INPUT

The DC-UPS requires one 12V VRLA battery to buffer the 24V output.

Battery voltage nom. DC 12V Use one maintenance-free 12V VRLA lead acid battery or

one

9.0 – 15.0V Continuously allowed, except deep discharge protection Battery voltage range

max. 35Vdc Absolute maximum voltage with no damage to the unit

typ. 7.4V Above this voltage level battery charging is possible Allowed battery sizes min. 3.9Ah max. 40Ah

max. 100mOhm See individual battery datasheets for this value Internal battery resistance Battery charging method CC-CV Constant current, constant voltage mode Battery charging current (CC-mode) nom. 1.5A Independent from battery size,

max. 1.7A Corresponding 24V input current see Fig. 8-2 End-of-charge-voltage (CV-mode) 13.4-13.9V Adjustable, see chapter 14 Battery charging time typ. 5h *) For a 7Ah battery typ. 17h *) For a 26Ah battery

Battery discharging current **) typ. 21A Buffer mode, 10A output current, 11.5V on the battery

typ. 0.3A Buffer mode, 0A output current

max. 50μA At no input, buffering had switched off, all LEDs are off

typ. 270mA At no input, buffering had switched off, yellow LED

typ. 10.5V At 0A output current Deep discharge protection ***) typ. 9.0V At 10A output current

*) The charging time depends on the duration and load current of the last buffer event. The numbers in the table represent a

fully discharged battery. A typical figure for a buffer current of 10A is 3h 20Min. for a 7Ah battery.

**) The current between the battery and the DC-UPS is more than twice t

battery voltage to a 24V level. This high current requires large wire gauges and short cable length for the longest possible buffer time. The higher the resistance of the connection between the battery and the DC-UPS, the lower the voltage on the battery terminals which increases the discharging current. See also chapter

***) To ensure longest battery lifetime, the DC-UPS has a battery deep discharge protection feature included. The DC-UPS stops

bufferin

g when the voltage on the battery terminals of the DC-UPS falls below a certain value. The yellow LED will show

“buffer time expired” for a period of 15 minutes after the unit stopped buffering.

Fig. 8-1 Battery discharging current

vs. output current, typ.

Battery Current

30A

2.5 7.5 10 15A12.55

A B C

Voltage on battery terminal of the DC-UPS:

10.5V

11V

12V

battery module which is listed in the chapter

accessories.

terminal of the DC-UPS, see Fig. 8-1 for other parameters

shows “buffer time expired” (max. 15 minutes)

he output current. This is caused by boosting the 12V

25 for more installation instructions.

Fig. 8-2 Required input current vs. input

voltage for battery charging

Input Current

1.5A

1.25

1.0

0.75

0.5

0.25

(

24 25 26 28V

)

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UB10.241

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 standard battery modules.

Buffer time with battery module UZK12.071 min. 19’12’’ At 5A output current *) min. 5’42’’ At 10A output current *) typ. 21’30’’ At 5A output current, see Fig. 9-1 **) typ. 6’45’’ At 10A output current, see Fig. 9-1 **) Buffer time with battery module UZK12.261 min. 99’30’’ At 5A output current *) min. 39’ At 10A output current *) typ. 130’ At 5A output current, see Fig. 9-1 **) typ. 55’ At 10A output current, see Fig. 9-1 **)

*) Minimum value includes 20% aging of the battery and a cable length of 1.5m with a cross section of 2.5mm2 between the

battery and the DC-UPS and requires a fully charged (min. 24h) battery.

**) Typical value includes 10% aging of the battery and a cable length of 0.3m with a cross section of 2.5mm

and the DC-UPS and requires a fully charged (min. 24h) battery.

Buffer Current

10A

Fig. 9-1

Buffer time vs. output current with the battery modules UZK12.071 and UZK12.261

120 150 210 240

180 27090

Buffer Time (Minutes)

515

2010 25 30 35 45 5040 55 60 65 70 75 80 85

The battery capacity is usually specified in amp-hours (Ah) for a 20h discharging event. The battery discharge is nonlinear (due to the battery chemistry). The higher the discharging current, the lower the appropriable battery capacity. The magnitude of the reduction depends on the discharging current as well as on the type of battery. High current battery types can have up to 50% longer buffer times compared to regular batteries when batteries will be discharged in less than 1 hour.

High discharging currents do not necessarily mean high power losse

s as the appropriable battery capacity is reduced with such currents. When the battery begins to recharge after a discharging 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). The battery datasheet needs to be studied and a determination of the expected buffer time can be made according to the following example:

between the battery

Min.

300

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Page 8

Example how to determine the expected buffer time for other battery types and battery sizes:

Step 1

Check the datasheet of the battery which is planned to be used and look for the discharging curve.

Sometimes, the individual discharging curves are marked with relative C-factors instead of current values. This can easily be converted. The C-factor needs to be multiplied with the nominal battery capacity to get the current value. E.g.: 0.6C on a 17Ah battery means 10.2A.

Fig. 9-2 Typical discharging curve of a typical 17Ah battery, curve taken from a

manufacturer’s datasheet

UB10.241

Step 2 Determine the required battery current. Use Fig. 8-1 “Battery discharging current vs. output current” to

get the battery current. Fig. 8-1 requires the average voltage on the battery terminals. Since there is a voltage drop between the battery terminals and the battery input of the DC-UPS, it is recommended to use the curve A or B for output currents > 3A or when long battery cables are used. For all other situations, use curve C.

Step 3 Use the de

(Discha UPS stops buffering due to the under-voltage lockout.

Step 4 De

Example: The buffer current: is 7.5A and a battery according Fig. 9-2 is used. The cable between the battery and the DC-UPS is

m and has a cross section of 2.5mm

Answer:

 According to Fig. 8-1, the battery current is 18A. Curve A is used since the battery current is > 3A and the

 According to Fig. 9-2, a buffer time (Discharging Time) of 30 Minutes can be determined. It is recommended

pending on Fig. 9-2, the buffer time needs to be reduced to take aging effects or guaranteed values

into ac

length of the cable is one meter.

duce this figure to approximately 24 minutes for a guaranteed value and to cover aging effects.

to re

termined current from Step 2 to find the appropriate curve in Fig. 9-2. The buffer time

rging Time) can be found where this curve meets the dotted line. This is the point where the DC-

count.

. How much is the maximum achievable buffer time.

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Page 9

UB10.241

10. EFFICIENCY AND POWER LOSSES

Efficiency typ. 97.8% Normal mode, 10A output current, battery fully charged Power losses typ. 2.9W Normal mode, 0A output current, battery fully charged typ. 5.5W Normal mode, 10A output current, battery fully charged typ. 5.0W During battery charging, 0A output current typ. 18.5W Buffer mode, 10A output current

Fig. 10-1 Efficiency at 24V, typ. Fig. 10-2 Losses at 24V, typ.

Efficiency vs. output current in normal mode

98%

97.5

97.0

96.5

96.0

95.5

95.0

94.5 39

5 7 11 13

15A

Power losses versus output current in normal mode

7 6 5 4 3 2 1 0

07.5

2.5 5 10 12.5

15A

11. FUNCTIONAL DIAGRAM

Fig. 11-1 Functional diagram

DC-UPS Control Unit

Input Fuse

24V

Power

Supply

12V Battery

Input

Battery

Reverse

Polarity

Protection

Battery

Tester

Cut-off

Relay

Battery

Charger

Step-up

Converter

(1) (2)

Ready Contact

Controller

(3) (4)

Buffering Contact

Electronic

Current

Limiter

(5) (6)

Replace Battery Contact

Output

Buffered

Load

Status LED (green) Diagnosis LED (yellow)

Check Wiring LED (red) Buffer-time Limiter

10s, 30s, 1m, 3m, 10m,

End-of-charge Voltage

(7)

Inhibit +

(8)

Inhibit -

*) Return current protection; This feature utilizes a Mosfet instead of a diode in order to minimize the voltage drop and power

losses.

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UB10.241

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 back up is required would the unit not be able to buffer. Therefore, a “check wiring” test is included in the DC-UPS. This connection is tested every 10 seconds by loading the battery and analyzing the response from the battery. If the resistance is too high, or the battery voltage is not in range, the unit displays “Check Wiring” with the red LED. At the same time the green “Ready” LED will turn off.

“State of Health” (SoH) test:

The battery has a limited service life and needs to be replaced in a fixed interval which is defined by the specified

rvice life (acc. to the Eurobat guideline), based on the surrounding temperature and the number of

se charging/discharging cycles. If the battery is used longer than the specified service life, the battery capacity will degrade. Details can be found in chapter However, it c the DC-UPS.

The battery quality test consists of different types of tests:

 During cha

 During operation:

A battery problem is indicated with the yellow LED (replace batte Please note that it can take up to 50 hours (with the largest size of battery) until a battery problem is reported. This should avoid nuisance error messages as any urgent battery problems will be reported by the “Check Wiring” test and create a warning signal. The battery tests require up to 50h uninterrupted operation. Any interruptions in the normal operation of the DC-UPS may result in the “Replace Battery” test cycle to start over.

When “Replace battery” is indicated, it is recommended to replace battery as soon as possible.

an detect a battery failure within the specified service life of the battery. Therefore a SoH is included in

rging: If the battery does not reach the ready status (see chapter 14) within 30h, it is considered The reason could be a broken cell inside the battery.

Once the battery is fully charged, a voltage drop test and a load test is performed alternately every 8 hours. Three of the tests must consecutively produce negative results to indicate a battery problem.

27.1. The battery SoH test can not determine a gradual loss in capacity.

to be defective.

ry pattern) and the relay contact “Replace Battery”.

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UB10.241

13. RELAY CONTACTS AND INHIBIT INPUT

The DC-UPS is equipped with relay contacts and signal inputs for remote monitoring and controlling of the unit.

Relay contacts:

Ready: Conta

Buffering: Contact is closed when unit is buffering. Replace Battery: Contact is closed when the unit is powere

Relay contact ratings max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load min 1mA at 5Vdc min. Isolation voltage max 500Vac, signal port to power port

Signal input:

Inhibit: The inhibit input disables buffering. In normal mode, a static signal is

Signal voltage max. 35Vdc Signal current max. 6mA, current limited Inhibit threshold min. 6Vdc, buffering is disabled above this threshold level max. 10Vdc Isolation nom. 500Vac, signal port to power port

Restriction apply when using the signal and relay contacts in a Haz-Loc environment:

The Buffering, Ready and Replace Battery contact is intended to be used for a separately investigated nonincendive field wiring and/

or field wiring apparatus. The DC-UPS may be located in a Class I, Division 2 (Group A, B, C or D) hazardous (classified) location. Associated apparatus must be installed in accordance with its manufacturer's control drawing and Article 504 of the National Electrical Code (ANSI/NFPA 70) for installation in the United States, or Section 18 of the Canadian Electrical Code for Installations in Canada. Selected associated apparatus must be third part listed as providing nonincendive field circuits for the application, and have Voc not excee

Non associated nonincendive field wiring apparatures shall not be connected in parallel unless this is permitted by the associated noni

ding Vmax, Isc not exceeding Imax.

ncendive field wiring apparatures approval.

ct is closed when battery is charged more than 85%, no wiring failure are recognized, input

voltage is sufficient and inhibit signal is not active.

d from the input and the battery quality test (SOH test)

reports a negative result.

7 +

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. See also section

27.1 for application hints.

Inhibit

8 -

3mA

5,1V

11/23

Page 12

Fig. 13-1 Contact control drawing for use in Haz-Loc

Input Output

Ready

DCUPS

Buffering

Replace Battery

Battery

Hazardous

Location

2 3

4 5

environments

Isc

Voc

Isc

Voc

Isc

Voc

Non Hazardous Location

Apparatus

UB10.241

Selected barriers must have entity parameters such that

V max, Isc < I max,

Voc <

Ci + Ccable, La > Li + Lcable.

Ca > For Ccable and Lcable, if the capacitance per foot or the inductance following values shall be used: Ccable = 60pF/foot and Lcable = 0.2µH/foot.

Contact current: I max = 50mA Contact voltage: V max. = 35V (DC or AC) Max. associated circuit capacitance Ci = 0 Max. associated circuit inductance Li = 0 No polarity requirement

per foot is not known, then the

12/23

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UB10.241

14. FRONT SIDE USER ELEMENTS

Power Port

A Quick-connect spring-clamp terminals, connection for input voltage,

output voltage and battery

Signal Port

B Plug connec

Connections for the Ready, Buffering, Replace Battery relay contacts and for the Inhibit input. See details in chapter . 13

Green Status LED

C Ready: Ba

voltage is sufficient and inhibit signal is not active.

Charging: Ba Buffering: Unit is i

Flashing pattern of the green status LED:

Yellow Diagnosis LED

Overload: Output has switched off due to long overload in buffer mode

or due to high temperatures.

Replace battery: Indicates a battery which failed the battery quality test

(SoH test). Battery should be replaced soon.

Buffer-time expired: Output has switched off due to settings of Buffer-

timer Limiter. This signal will be displayed for 15 minutes.

Inhibit active: Indicates that buffering is disabled due to an active inhibit

signal.

Flashing pattern of the yellow diagnosis LED:

Red Check Wiring LED

This LED indicates a failure in the installation (e.g

F Buffer-time Limiter:

User accessible dial which limits the maximum buffer time in a buffer event to save battery energy. When the

battery begins to recharge after a discharging event, the process is completed much faster since only the energy which was taken out of the battery needs to be “refilled”. The following times can be selected: 10 seconds, 30 seconds, 1 minute, 3 minutes, 10 minutes or infinity (until battery is flat) which allows buffering until the deep discharge protection stops buffering.

G End-of-charge-voltage Selector:

The end-of-charge-voltage shall be set manually according to the expec

located. The dial on the front of the unit allows an continuously adjustment between +10 and +40°C. 10°C will set the end-of-charge-voltage to 13.9V, 25°CÆ13.65V and 40°CÆ13.4V. If in doubt about the expected temperature, set the unit to 35°C.

tor with screw terminals, inserted from the bottom.

ttery is charged > 85%, no wiring failure is recognized, input

ttery is charging and the battery capacity is below 85%.

n buffer mode.

ON OFF

. too low input voltage), wiring, battery or battery fuse.

Charging

Buffering

Overload

Replace

Buffer time

ted temperature in which the battery is

Ready

Battery

expired

Inhibit

active

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UB10.241

15. TERMINALS AND WIRING

Type Bi-stable, quick-connect spring-

Solid wire 0.5-6mm Stranded wire 0.5-4mm 0.2-1.5mm AWG 20-10AWG 22-14AWG Ferrules Allowed, but not required Allowed, but not required

Pull-out force 10AWG:80N, 12AWG:60N,

Tightening torque Not applicable 0.4Nm, 3.5lb.in Wire stripping length 10mm / 0.4inch 6mm / 0.24inch

Fig. 15-1 Spring-clamp terminals, connecting a wire

Insert the wire

To disconnect wire: reverse the procedure

Power terminals Signal terminals

Plug connector with screw te clamp terminals. IP20 Fingertouch-proof. Suitable for fieldand factory installation. Shipped in open position.

14AWG:50N, 16AWG:40N according to UL486E

Close the lever

2 2

construction with captive screws for 3.5mm slotted

screwdriver. Suitable for field- and factory installation.

Shipped in open position. To meet GL requirements,

unused terminal compartments should be closed.

0.2-1.5mm

Not applicable

Instructions:

a) Use

b) Follow c) Ensure that all

d) Up to two stranded wires with the same c

appropriate copper cables, that are designed

for an operating temperature of 60°C

national installation codes and regulations!

terminal connection!

section are permitted in one connection point

rminal. Finger-touch-proof

strands of a stranded wire enter the

ross

16. RELIABILITY

Lifetime expectancy min. 137 400h At 10A output current, 40°C min. > 15 years At 5A output current, 40°C min. > 15 years At 10A output current, 25°C MTBF SN 29500, IEC 61709 886 000h At 10A output current, 40°C 1 482 000h At 10A output current, 25°C MTBF MIL HDBK 217F 397 900 At 10A output current , 40°C, ground benign GB40 545 000 At 10A output current , 25°C, ground benign GB25

The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s manufacturer specification. The prediction model allows a calculation of up to 15 years from date of shipment.

MTBF st reliability of a device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.

ands for Mean Time Between Failure, which is calculated according to statistical device failures and indicates

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UB10.241

17. EMC

The unit is suitable for applications in industrial environment as well as in residential, commercial and light industry environment without any restrictions. CE mark is in conformance with EMC guideline 89/336/EEC and 93/68/EEC and the low-voltage directive (LVD) 73/23/EEC, 93/68/EEC.

A detailed EMC Report is available on request.

Generic standards

EMC Immunity

Electrostatic discharge EN 61000-4-2 Contact discharge

Electromagnetic RF field EN 61000-4-3 80MHz-1GHz 10V/m Criterion A Fast transients (Burst) EN 61000-4-4 Out- and input lines 2kV Criterion A Signal lines **) 2kV Criterion A

Surge voltage EN 61000-4-5 Output + Æ -

Conducted disturbance EN 61000-4-6 0,15-80MHz 10V Criterion A

*) DIN-Rail earthed **) Tested with coupling clamp

EN 61000-6-3, EN 61000-6-4 Generic standards

EMC Emission

Conducted emission EN 55022 Input lines Class B *) EN 55022 Output lines Class B *) Radiated emission EN 55011, EN 55022 Class B

This device complies with FCC Part 15 rules. Operation is subjected to the following two conditions: (1) this device may not cause harmful interference, and (2) this de

vice must accept any interference received, including interference that may cause undesired operation.

*) Informative measurement with voltage probe

Switching frequencies

Switching frequency of boost converter 100kHz Constant frequency Switching frequency of electronic output curre Switching frequency of battery charger 19.5kHz Constant frequency

EN 61000-6-1, EN 61000-6-2

nt limitation 78kHz Constant frequency

8kV

Air discharge

Input + Æ + / - Æ housing

The DC-UPS has three convert

switching frequencies included.

15kV

500V 500V 500V

Criterion A*) Criterion A *)

Criterion A Criterion A Criterion A

ers with three different

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UB10.241

18. ENVIRONMENT

Operational temperature -25°C to +70°C (-13° to +158°F) For the DC-UPS control unit.

Derating 0.43A/°C

0.25A/°C

Storage temperature -40 to +85°C (-40° to +185°F) Storage and transportation, except battery

Humidity 5 to 95% r.H. IEC 60068-2-30

Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g IEC 60068-2-6 Shock 30g 6ms, 20g 11ms IEC 60068-2-27 Altitude 0 to 6000m Approvals apply only up to 2000m Over-voltage category III EN 50178 II EN 50178 above 2000m altitude Degree of pollution 2 EN 50178, not conductive

Fig. 18-1 Output current vs. ambient temperature Fig. 18-2 Output current vs. ambient temperature

Allowable Output Current in Normal Mode

15A

12.5

7.5

2.5

-25 0 20 40

Ambient Temperature

70°

Allowable Output Current in Buffer Mode

15A

12.5

7.5

2.5

The ambient temperature is defined 2cm below the unit.

Keep battery in a cooler environment! +60°C to +70°C (+140°F to +158°F),

normal mode see Fig. 18-1 +60°C to +70°C (+140°F to +158°F),

buffer mode see Fig. 18-2

Do not energize while condensation is present

-25 0 20 40

Ambient Temperature

70°

19. PROTECTION FEATURES

Output protection Electronically Output over-voltage protection

in buffer mode

typ. 32Vdc max. 35Vdc

Degree of protection IP20 EN/IEC 60529 Penetration protection > 3.5mm E.g. screws, small parts Reverse battery polarity protection yes Max. –35Vdc; Wrong battery voltage protection yes Max. +35Vdc (e.g. 24V battery instead of 12V battery) Battery deep discharge protection yes The limit is battery current dependent Over temperature protection yes Output shut-down with automatic restart Input over-voltage protection yes Max. 35Vdc, no harm or defect of the unit Internal input fuse 25A, blade type No user accessible part, no service part

protected against overload, no-load and short-circuits

In case of an internal defect, a redundant circuitry limits the maximum output voltage. The output automatically shuts-down and makes restart attempts.

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UB10.241

20. SAFETY

Output voltage SELV IEC/EN 60950-1 PELV EN 60204-1, EN 50178, IEC 60364-4-41

Class of protection III PE (Protective Earth) connection is not required Isolation resistance > 5MOhm Power port to housing, 500Vdc Dielectric strength 500Vac Power port to signal port 500Vac Power port / signal port to housing

Touch current (leakage current) The leakage current which is produced by the DC-UPS itself depends on the input

Max. allowed voltage between any input, 60Vdc or 42.4Vac

ge ripple and need to be investigated in the final application.

volta For a smooth DC input voltage, the produced leakage current is less than 100μA.

output or signal pin and ground:

21. APPROVALS

UL 508

UL 60950-1

IEC 60950-1

UL 1604 RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and

The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations as well as for Class I

Marine

one 2 Groups IIA, IIB and IIC locations. Substitution of components may impair suitability for Class I Division 2 environment. Do not disconnect equipment unless power has been switched off. Wiring must be in accordance with Class I, Division 2 wiring methods of the National Electrical Code, NFPA 70, and in accordance with other local or national codes.

18WM

IND. CONT. EQ.

IECEE

CB SCHEME

ABS

LISTED E198865 listed for use in U.S.A. (UL 508) and C

anada (C22.2 No. 14-95)

Industrial Control Equipment

RECOGNIZED E137006 recognized for the use in U.S.A. (UL 609 Information Technology Equipment, Level 5

CB Scheme, Information Technology Equipment

Canada (C22.2 No. 213-M1987) Hazardous Location Class I Div 2 T4 Groups A,B,C,D and Class I Zone 2 Groups IIA, IIB and IIC

GL (Germanischer Lloyd) classified and ABS (Americ Shipping) PDA for marine and offshore applications.

Environmental category: C, EMC2

50-1) and Canada (C22.2 No. 60950)

an Bureau for

22. FULFILLED STANDARDS

EN/IEC 60204-1 Safety of Electrical Equipment of Machines

EN/IEC 61131 Programmable Controllers

EN 50178, IEC 62103 Electronic Equipment in Power Installations

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UB10.241

23. USED SUBSTANCES

The unit does not release any silicone and is suita

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, wires and cables are not PVC insulated.

The materials used in our production process do not include the following toxic chemicals: P

olychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica

ble for the use in paint shops.

24. PHYSICAL DIMENSIONS AND WEIGHT

Width 49mm / 1.93’’ Height 124mm / 4.88’’ Plus height of signal connector plug Depth 117mm / 4.61’’ Plus depth of DIN-rail Weight 530g / 1.17lb DIN-Rail Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.

The DIN-rail height must be added to the depth (117mm) to calculate the total required installation depth.

Electronic files with mechanical data can be downloaded at www.pulspower.com

Fig. 24-1 Side view Fig. 24-2 Front view

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UB10.241

25. INSTALLATION NOTES

Mounting:

The power terminal shall be located on top of the unit. An appropriate electrical and fire end-product enclosure should be considered in the end use application.

Cooling: Convec

Installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended

en loaded permanently with full power. In case the adjacent device is a heat source, 15mm clearance are

recommended.

Risk of electrical shock, fire, personal injury or death!

Turn power off and disconnect battery fuse before working on the DC-UPS. Protect against inadvertent re-powering. Make sure the wiring is correct by following all local and n Use caution to prevent any foreign objects from entering into the housing. Do not use in wet locations or in areas where

Service parts: The unit does not contain any service parts. The tripping of an internal fuse is c or malfunctioning should occur during operation, immediately turn power off and send unit to the factory for inspection!

Wiring and installation instructions:

(1) Connect the power supply to the input terminals of the DC-UPS. (2) Connect the battery to the battery terminals of the DC

cabinet or in a place where the battery will not be heated up by adjacent equipment. Do not install the battery in airtight housings or cabinets. The battery should be installed according to EN50272-2, which includes sufficient ventilation. Batteries store energy and need to be protected against energy hazards. Use a 30A battery fuse typ ATO® 257 030 (Littelfuse) or similar in the battery path. The battery fuse protects the wires between the battery and the DC-UPS. It also allows the disconnection of the battery from the DC-UPS which is recommended when working on the battery or DC-UPS. Disconnect battery fuse before connecting the battery.

Please note: Too small or too long wires between the DC-UPS and the battery c

result in a malfunction of the DC-UPS. Do not use wires smaller than 2.5mm 2x1.5m (cord length 1.5m). Avoid voltage drops on this connection.

(3) Connect the buffered load to the output terminals

allowing load circuits to be easily split into buffered and non buffered sections. Noncritical loads can be connected directly to the power supply and will not be buffered. The energy of the battery can then be used in the circuits which requires buffering.

(4) Install the fuse when the wiring is finishe

Fig. 25-1 Typical wiring diagram

tion cooled, no forced air cooling required. Do not obstruct air flow!

ational codes. Do not open, modify or repair the unit.

moisture or condensation can be expected.

aused by an internal fault. If damage

-UPS. It is recommended to install the battery outside the

an shorten the buffer time or can

(or 12AWG) and not longer than

of the DC-UPS. The output is decoupled from the input

24V unbuffered branch

24V buffered branch

24V

Power supply

NLPE

+-+-+

24V

12V

BAT

DC-UPS

UB10.241

24V

OUT

12V

Battery

Buffered

load

Unbuffered

load

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UB10.241

26. 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 or can save shipping and logistic costs. See individual datasheets for detailed information.

UZK12.071 UZK12.261

Battery type Standard version

Service life 3 to 5years 10 to 12years According to EUROBAT guideline Dimensions 155x124x112mm 214x179x158mm Width x height x depth Weight 3.2kg 9.9kg DIN-Rail mountable yes no Order numbe UZO12.07 UZO12.26 Mounting bra UZB12.071 UZB12.261 Replacement b

Fig. 26-1 UZK12.071 Fig. 26-2 UZK12.261

r UZK12.071 UZK12.261 Battery module

12V, 7Ah

High current version 12V, 26Ah

VRLA lead-acid maintenance free battery

cket without battery

attery only

ZM1.WALL Wall / Panel mounting bracket This bracket is used to mount the DC-UPS units onto a fla

brackets and the black plastic slider of the DC-UPS have to be removed so that the two surface brackets can be mounted.

Fig. 26-3 ZM1.WALL Wall / Panel Mounting Bracket Fig. 26-4 Assembled Wall / Panel Mounting Bracket

t surface without utilizing a DIN-Rail. The two aluminum

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UB10.241

27. APPLICATION NOTES

27.1. 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 usually is specified according to the Eurobat guideline or according to the manufacturer’s specifications.

The design life is the estimated life based on laboratory cond recommended float voltage condition. According to the Eurobat guideline, design lives have been structured into the following different groups:

3 - 5 years:

6 - 9 years:

10 - 12 years:

A battery failure within the specified design life of the function (broken cell, defect connection, …) and will be detected and reported by the periodical battery tests which are included in the UB10.241 DC-UPS control unit.

If the operational parameters differ from those which are specified for the design life, an earlier change of the battery might be necessary. The “real life” is called service life and is defined as the point at which the cell’s actual capacity has reached 80% of its nominal capacity. At the end of the service life the capacity degrades much faster, so that a further use of the battery is not recommended.

Temperature effect:

The temperature has the most impact in th of the battery begins. The wear-out results in a degradation of battery capacity. See Fig. 27-1 for details.

Effect of discharging cycles

The number as well as the depth of discharging cycles is limited earlier than the calculated service life if the battery exceeds the numbers and values of Fig. 27-2.

Other effects which shortens the service life

Guidelines for a long battery service life:

This group of batteries is very popular in standby applications and in small emergency equipment.

This represents a 4 years design life with a production tolerance of ±1 year.

This group of batteries is usually used when an improved life is required.

This represents a 7.5 years design life with a production tolerance of ±1.5 years.

This group of batteries is used when in applications where longest life and highest safety level are

required. This represents a 11 years design life with a production tolerance of ±1 year.

battery usually results in a complete loss of the battery

e service life. The hotter the temperature, the earlier the wear-out phase

 Ove

 Cha

 Exc

 Plac  Do not place the battery near heat generating devices.  Do not store discharged batteries.  Do not discharge the battery more than necessary. Set buffer time limiter to the required buffer time.  When c

rcharging and deep discharging shortens the service life and should be avoided. Thanks to the single battery concept of the UB10.241, the end-of-charge-voltage can be set very precisely to the required value an thereby avoiding unnecessary aging effects.

rge retention is important to get the longest battery life. Stored batteries which are not fully charged

age faster then charged batteries. Batteries which are not in use should be recharged at least once a year.

essive float charge ripple across the battery has an effect of reducing life and performance. The UB10.241 does not produce such a ripple voltage. This effect can be ignored when the battery is charged with the UB10.241.

e the battery in a cool location: E.g. near the bottom of the control cabinet.

hoosing the battery capacity, always try to get the next higher capacity than required. The depth of

discharge reduces the service life of the battery and limits the number of cycles. See Fig. 27-2.

ition, and is quoted at 20°C using the manufacturer’s

. A replacement of the battery might be necessary

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Page 22

UB10.241

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 battery module UZK12.071)  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. 27-1 curve A, a 2 years s

ervice life can be expected for an ambient temperature of 30°C.

Number of discharging cycles: 2 years * 365 cycles = 730cycles in 2 years. Ac

cording to Fig. 27-2, curve C has to be used (only 25% of battery capacity is required). 730 cycles have only a gligible influence in a battery degradation and can be ignored.

Result: The battery shall be replaced after 2 years. Please note that the battery degrading begins from the production date (check date code on the battery) which may shorten the replacement intervals.

Fig. 27-1 Service life versus ambient

temperatures, typ *)

Service Life in Years

9 8

7 6

5 4

3 2

20°C

Ambient Temperature

30°C 35°C

25°C

Design Life of Battery

3-5 Years

6-9 Years

10-12 Years

40°C

45°C

Fig. 27-2 Cell capacity degradation vs. discharging

Cell Capacity

120%

100%

80%

60%

40%

20%

UZK12.071 UZK12.261

200 400 600 800 1000 1200

cycles *)

Depth of discharge

A: 100% B: 50% C: 30%

Number of Discharging Cycles

160 240 320 400 480

*) datasheet figures from battery manufacturer

27.2. PARALLEL AND SERIAL USE

Do not use the DC-UPS in parallel to increase the output power. However, two units of the DC-UPS can be paralleled for 1+1 redundancy to gain a higher system reliability.

Do not use batteries in parallel, since the battery quality test might create an error message. Do not connect two or more units in series for higher output voltages. Do not connect two or more units in a row to get longer hold-up times.

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UB10.241

27.3. 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 c be supplied from the output of the DC-UPS.

Fig. 27-3 Wiring example for inhibit input

12V

Battery

+ -+ -

Output

Power Supply

Input

onnect a service switch. Therefore, the inhibit signal can

+ -+ - + -

BAT

24V

12V

DC-UPS

UB10.241

Signal Port

OUT

24V

+ -

Inhibit

Buffered

Load

Service

Switch

27.4. TROUBLESHOOTING

The LEDs on the front of the unit and relay contacts indicate about the actual or elapsed status of the DC-UPS. Please see also chapter 14.

The following guidelines provide instructions for fixing the most common failures and problems. Always start with the most likely and easiest-to-check condition. Some of the suggestions may require special safety precautions. See notes in section

“Check wiring” LED is on

DC-UPS did not buffer

DC-UPS stopped buffering

Output has shut down Cycle the input power to reset the DC-UPS

DC-UPS constantly switches between normal mode and buffer mode

25 first.

Check correct wiring between the battery and the DC-UPS Check battery fuse. Is the battery fuse inserted or blown? Check battery voltage (must be typically between 7.4V and 15.1V) Check input voltage (must be typically between 22.8V and 30V) Check battery polarity

Inhibit input was set Battery did not have enough time to be charged and is still below the deep discharge protection limit.

Buffer time limiter stopped buffering Æ set buffer time limiter to a higher value Deep discharge protection stopped buffering Æ use a larger battery, or allow sufficient time for charging the battery Output was overloaded or short circuit Æ reduce load

t DC-UPS cool down, over temperature protection might have triggered.

The supplying source on the input is too small and can not deliver sufficient current Æ Use a larger power supply or reduce the output load

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