Dycon D2330 User Manual

User Manual

D2330 Test Set/Service Tool for

D243X-series, EN54-certified,

24VDC Switched-

Mode Power

Supply Units

Dycon Power Solutions Ltd

Unit A, Cwm Cynon Business Park

Mountain Ash

South Wales

CF45 4ER

United Kingdom

Tel: [phone]

www.dyconpower.com [e-mail]

D2330-060116-V1.1

D2330-060116-V1.1

Page 3 of 10 D2330-060116-V1.1

D2330 PSU Test Set / Service Tool Instructions

Test Set / Service Tool Overview

The Test Set / Service Tool is compatible with the Dycon range of EN54-4 24V power supplies:

• D2431-7 : 1.5A 24V power supply in medium box (2 x 7.5/8 Ah batteries)

• D2433-7 : 3.0A 24V power supply in medium box (2 x 7.5/8 Ah batteries)

• D2433-17 : 3.0A 24V power supply in large box (2 x 17.5/18 Ah batteries)

• D2435-17 : 5.0A 24V power supply in large box (2 x 17.5/18 Ah batteries)

The D2330 allows the installer to monitor the performance of the power supply, system currents and voltages,
the condition of the batteries and a log of PSU events and faults. It can also be used to calibrate and test power

supplies.

Test Set / Service Tool Description

The D2330 is supplied in a removable tough rubber boot with hinged stand:

A USB charging socket and RJ45 PSU connection socket are located at the top of the test set:

Page 4 of 10 D2330-060116-V1.1

Programmer Keypad

The programmer has a 15-key membrane keypad that is used to navigate through all the menus and enter and
retrieve information. The up and down keys will scroll through the menus, the enter key is used to select menus
and enter commands, the escape key allows the user to quit menus. The right arrow delete key is for future use

and is not used in this version.

0

5

8 97

64

321

4 X 20 Character

Backlit LCD Display

Menu
Navigation
Down Key

Menu

Navigation Up

Key

Enter Key

Escape Key

To Turn the Programmer On

Press any of the left-hand column keys

To Turn the Programmer Off

Press the escape key repeatedly until ‘Turn Off?’ is shown and press enter. If the unit is accidentally left on
continuously, the programmer will automatically power down after 15 minutes of non-use. The test set will stay

on continuously when the charging adapter is plugged-in and charging.

Test Set / Service Tool Specifications

SPECIFICATIONS

Charging

USB Micro B, 5V, 450mA Maximum

Charge Time

2 hours to full charge

Battery

Rechargeable LiPo battery, 3.7V nominal, 800mAH

Battery Life

2 days continuous operation

Test Lead

I Metre FCC-68 (RJ45) to 5-way 2.5mm Molex KK receptacle

Display

Backlit 4 x 20 character LCS display, readable in direct sunlight

Communication interface

9600 baud, no parity, one stop bit, 5V logic, asynchronous serial

Compatibility

D2431-7, D2433-7, D2433-17, D2435-17

Accuracy

+/- 2 Least significant digits. Actual measurements are derived

from PSU

Dimensions

76.5mm x 127mm x 24mm without boot, 93mm x 155mm x

36mm with boot

Weight

140gm without boot, 310gm with boot

Page 5 of 10 D2330-060116-V1.1

Warning
Before using the test set / service tool, ensure that the AC power supply is switched off before
removing the lid and plugging in the test cable.

Programmer Menus

Main Menu

This menu selects the various functions of the test set. When the test set is first switched-on a screen with the
software version is shown briefly in the lower right hand corner (‘nnn’ on the illustration below). Pressing the

up/down arrows steps through the functions. Pressing enter will select the menu of interest.

Dycon

D2430 Series

Test Set

3DL test set nnn

Turn Off

Information

Measurements

Commands

Faults and Status

Calibration

Advanced Information
Refer to manual
For details

Measurements

The measurement menu is used to select the various voltages, currents generated by the power supply and the
battery impedance in ohms. The menu is accessed by pressing enter when ‘Measurements”’ prompt is

shown:

PSU Current
Measurements

Measurement Menu

Battery Impedance

Measurement Menu

PSU Voltage
Measurements

Measurement Menu

Output Currents

Measure Amps Menu

Battery Charging
Current

Measure Amps Menu

Battery Voltages

Measure Volts Menu

Output Voltages

Measure Volts Menu

Charging Voltage

Measure Volts Menu

Page 6 of 10 D2330-060116-V1.1

PSU Current Measurements

Pressing ‘enter’ accesses the two current measurement menus by scrolling up and down using the arrows.

Output Currents

After pressing enter, the display will briefly
show this message, whilst connecting….
Followed by a typical display like this:

The bottom ‘Outputs’ display shows the total current being used by outputs 1 and 2. This does not include the

battery charging current. You can quit the Output Currents display by pressing the up arrow key.

NOTE: There is a 300mA reserve of battery current, for example if a 5A PSU is already providing 5A, an extra
300mA (depending on the battery charge condition) can also be provided. In this case a total of 5.3A is being

supplied.

Battery Charging Current

Selected by pressing ‘enter’, the following display is shown:
The current shown is typical of a fully charged battery.

NOTE: If the battery current is varying wildly, this will probably be due to a discharged battery taking significant

charging current and sharing the total current capacity with the output load, where the load is varying.

PSU Voltage Measurements

Three different menus are available in this measurement mode, these can accessed by pressing ‘enter’ and

using the scroll arrows.

Battery Voltages

When selected, the following display is shown:

The battery voltages shown is typical of a fully charged set of batteries. Battery 1 and Battery 2 voltages are

shown separately, the bottom Batteries voltage display is the sum of the individual battery voltages.

NOTE: The individual battery voltages will seldom be identical, but should be balanced to at least 1V with
respect to each other. Actual voltage values will depend on the charge state and temperature and are not

necessarily related to the PSU charging voltage.

Output Voltages

When selected, this display is shown:

The output voltages will vary according to temperature and load current and will not necessarily be identical.

NOTE: Voltage at the load will vary according to current causing voltage drop by the installation wiring. There
will also be a small difference (a few tens of millivolts) caused by the PSUs small internal resistance needed for
current monitoring. This is will be reflected by a small variations of the displayed voltage readings shown on the

screens and is normal.

Charging Voltage

When selected, this display is shown:

The charging voltage is the internal PSU voltage used for battery charging when AC power is present and is

dependent on temperature.

NOTE: The charging voltage, battery voltage and output voltages will not necessarily be the same depending

on mode and conditions.

Waiting for Data

Output 1 = 1.20A
Output 1 = 0.30A
Outputs = 1.50A

Battery Charging
Current

0.02A

Battery 1 = 13.34V
Battery 1 = 13.65V
Batteries = 26.99V

Output 1 = 27.01V
Output 2 = 27.03V
Voltage at load will
drop with current

Charging = 27.00V

Page 7 of 10 D2330-060116-V1.1

Battery Impedance

When selected the following display is shown:

‘Rbat’ is the combined impedance (resistance) of the battery, battery leads, connectors and PSU charging path

and must not exceed 0.177Ohms.
If the test fails then a typical display might show the following:

If the test is attempted when the battery is not fitted or AC power is not present

the following display is shown:

Information

The information menu is used to view the software version of the PSU firmware and the PSU type.

Software Version

Information Menu

PSU Hardware Type

Information Menu

Software Version

When selected the following display is shown. The two characters before

and adjacent to the “V” indicate the version:

PSU Hardware Type

The display shows the PSU hardware type:
Currently there are three types:
24V 1.5A: D2431-7 (2 x 7Ah batteries)
24V 3A: D2433-7 (2 x 7Ah batteries)
24V 3A D2433-17 (2 x 17Ah batteries)
24V 5A: D2435-17 ((2 x 17Ah batteries)

Commands

The command menu remotely controls the switching of the two outputs in addition to the two local control

inputs.

OP1 Control

Command Menu

OP2 Control

Command Menu

OP1 Control

The OP1 control screen is shown opposite. The first line displays the current
output status, either “On” or “Off” and is updated in real time. The second line
indicates if local or serial control is in operation in real time. When ‘Serial’
control is selected then numeric keys can be used to control the output.
Number ‘1’ switches the output on and ‘2’ switches the output off. Numbers ‘4’and ‘5’ select between serial and

local control.

Battery Test Results
Rbat = 0.095 Ohms
Test Passed
Limit 0.177 Ohms

Waiting For Data
Fault Halted Test!

Battery Test Results
Rbat = 0.186 Ohms
Test Failed!
Limit 0.177 Ohms

Version Number
EN54PSU08V

PSU Hardware Type
24V 1.5A

OP1 On
OP1 Local Control
1=On 2=Off
4=Local 5=Serial

Page 8 of 10 D2330-060116-V1.1

NOTE: When the control function is used to switch outputs, care has to be taken to return the PSU to the local

control condition, otherwise the local control inputs on the PSU will be ignored.

OP2 Control

The OP2 control screen is shown opposite in serial mode with the output off:
Please see above for operation.

Faults and Status

This suite of functions display overall status of the power supply with informative, multiple data type screens for
‘at a glance’ user information. Faults and a fault log is also displayed here with a user option of erasing the fault

log so fresh history can be recorded.

Output and PSU
Status

Fault & Status Menu

Battery Charging and Current
Share Status

Fault & Status Menu

Temp. Compensation
Status

Fault & Status Menu

Fault Log

Fault & Status Menu

Erase Fault Log

Fault & Status Menu

Output and PSU Status

A typical PSU and Output status is displayed in the adjacent screen:
The PSU status is shown as follows:

First line: Output switched status, either On or Off
Second line: Output voltage
Third line: Output current
Fourth Line: AC On or Off, PSU fault status, OK or Fail

NOTE: The Fail PSU status is displayed if any of the faults other than AC power failure are pending.

Battery Charging and Current Share Status

A typical battery status is displayed in the adjacent screen:
The battery status is shown as follows:

First line: Battery charging current and voltage
Second line: Output 1 and 2 combined current and AC power status
Third line: Total current provided by the PSU, i.e. battery and combined current outputs with PSU fault status
Fourth Line: Battery 1 and 2 individual voltages

NOTE: With a fully discharged battery the PSU will automatically any used capacity to charge the battery. For
example, if 3 amps was taken from a D2435 5A PSU, then 2A would be diverted to charging the battery; in this

OP2 Off
OP1 Serial Control
1=On 2=Off
4=Local 5=Serial

O/P1 = On O/P2 = On

26.95V 26.90V

0.28A 0.79A
AC On PSU OK

Battery = 0.65A 26.88V
OP1&2=0.86A AC ON
Total =1.51A PSU OK
B1=13.46V B2=13.42V

Page 9 of 10 D2330-060116-V1.1

way, the PSU shares capacity with the outputs having the highest priority. A fully discharged battery will always
be charged at a minimum of 300mA. If a D2433 is supplying all of its 3A capacity to its outputs, then the battery

would be charged with a reserve of 300mA. In this case the total current would be 3.3A.

Temperature Compensation Status

This screen shows the Temperature compensation status:
The temperature compensation data is displayed thus:­First line: Temperature, this is measured by a probe located
between the two standby batteries
Second and third line: Actual charging voltage being delivered to the battery, internally within the PSU.

Fourth line: Ideal charging voltage, the test set has a mathematical model of the ideal theoretical voltage that
should be used to charge the batteries at any given temperature. The actual measured voltage should be

between +/- 70millivolts of the displayed actual voltage for maximum battery performance.

NOTE: In this way the screen display can be used for checking that the battery is being charged correctly
between specified limits. The sample screen shot is an actual reading taken off a real, randomly selected PSU,
the actual and ideal voltages should track between these limits with temperature and will not necessarily be

identical as shown.

Fault Log

The fault log records all fault events that have occurred since the log was cleared:

A list of 11 fault events are shown below:

1. SMPS Fault: Switched Mode Power Supply internal low voltage fault,
supply is less than 20V.

2. PSU over 32V and PSU shutdown: Over-voltage fault and subsequent shutdown.

3. O/P1 fuse fault: Output 1 fuse fault.

4. O/P2 fuse fault: Output 2 fuse fault.

5. PSU under minimum battery charging voltage fault: Inability to correctly charge the battery
because voltage is too low fault.

6. PSU not charging battery fault: Charging circuit malfunction fault.

7. Battery lead disconnected fault: One or both batteries are disconnected.

8. Battery high resistance fault: Battery impedance greater than 177millohm limit when being load
tested.

9. Battery 1 under 11.5V fault: Battery 1 low voltage fault.

10. Battery 2 under 11.5V fault: Battery 2 low voltage fault.

11. Battery under 22V while charging fault: Catastrophic battery fault where total battery voltage is less

than 22 volts when charging is applied.

The log is scrolled through by pressing the ‘down’ key and the log events will be displayed in chronological
order, most recent displayed first. When the end of the log is reached this message “-----End of Log----“ will

be displayed.
If the log is empty, ‘No faults logged’ will be displayed when attempting to view the log:
Multiple events of one type will only be appear once in the log to prevent the log from overfilling.

Erase Fault Log

This menu erases the current log enabling fresh events to be recorded. When ‘enter’ is pressed the log will be

erased and the display will show: ‘log erased’

Calibration

The calibration menu allows on-site calibration of the PSU. All PSUs are calibrated at the factory as a part of
their automated test procedure and normally do not require calibrating for the rest of their service lifetime.

However in extreme circumstances, e.g. operating in extremes of temperature, recalibration can be worthwhile.

Temperature = 31.0C
Charging Voltage:
Actual = 26.90V
Ideal = 26.90V+/-0.07V

Press down key to
scroll through faults

O/P1 fuse fault

Page 10 of 10 D2330-060116-V1.1

Calibrate Charging

Voltage

Calibration Voltage

Calibrate Battery
Current Monitor
Disconnect BAT1

Calibration Voltage

Calibrate Output 1
Current Monitor
Test Will Pulse O/P!

Calibration Voltage

Calibrate Output 2
Current Monitor
Test Will Pulse O/P!

Calibration Voltage

Calibrate Charging Voltage

When ‘enter’ is pressed the display will show:
‘Calibration Done’

After a short pause this display will be replaced with:

This display is described under the Temperature Compensation status section.

Note: There is a ‘hidden”’Advanced Information screen that can be accessed by pressing the ‘down’ arrow.

This information is useful only to trained technicians.

Calibrate Battery Current Monitor

Before calibrating, battery 1 must be disconnected as prompted. If the battery is not disconnected then

‘Disconnect Battery!’ will be displayed and the procedure will have to be started all over again.
When the calibration is completed successfully the display will show:

‘Calibration Done’

Note: There is a ‘hidden”’Advanced Information screen that can be accessed by pressing the ‘down’ arrow.

This information is useful only to trained technicians.

‘Calibrate Output 1’
When ‘enter’ is pressed the display will show:

‘Calibration Done’

Note: There is a ‘hidden”’Advanced Information screen that can be accessed by pressing the ‘down’ arrow.

This information is useful only to trained technicians.

‘Calibrate Output 2’

Please see above.

Temperature = 31.0C
Charging Voltage:
Actual = 26.90V
Ideal = 26.90V+/-0.07V