Puls UB20.241 Data Sheet

UB20.241

DC-UPS C

Input

Output voltage

in power supply mode

22.5V, 24V, 25V, 26V (selectable)

in battery mode

Output current

25A continuous 30A for 4s

in power supply mode

20A continuous 30A for 4s

in battery mode at 22.5V

Allowed battery sizes

3.9 – 150Ah

2 batteries in series, each 12V

Buffer time

6min 45s

at 20A, 7Ah

16min 47s

at 20A, 12Ah

2h 49min

at 20A, 65Ah

6h 20min

at 20A, 140Ah

Temperature range

-40°C to +70°C

operational

Derating

Dimensions

W x H x D

Weight

IND. CONT. EQ.

-Series

ENERAL DESCRIPTION

The UB20.241 uninterruptible power supply controller (DC-UPS) is used in addition with a 24V power supply and batteries to bridge power failures or voltage fluctuations. This configuration can prevent expensive downtimes, long restart cycles and loss of data.

A unique feature of the UB20 series is the constant voltage in battery mode, which will not change as the batteries discharge. The buffer voltage in battery mode can be set to four different output values. Another feature is the utilization of two independent battery chargers for the two 12V-batteries in series. This feature makes matching batteries unnecessary and allows for precise battery charging, testing and optimized usage of the battery capacity to achieve the longest battery service life.

The UB20.241 includes many battery diagnostic functions that ensure a reliable operation of the entire system. Furthermore, a temperature controlled charging extends the life of the batteries. It also includes a selectable buffer time limiter as well as ready, buffering and replace battery contacts. For safety and maintenance, an inhibit input signal is included which prevents a battery backup.

24V, 20A, DC-UPS

ONTROL UNIT

 No Change in Output Voltage in Battery Mode  Selectable Output Voltages in Battery Mode  1-Battery-Concept

Each 12V Battery is Charged and Monitored Separately for Longest Battery Life

 Precise Battery Charging by Using a Temperature Sensor  Battery Size Selector for Small or Large Batteries  50% BonusPower  High Breaking Capacity for Branch Protectors  Smart Battery Diagnostics and Monitoring Functions  3 Year Warranty

, 30A for up to 4s

HORT-FORM DATA

voltage DC 24V

same as input

voltage

0.5A/°C 46x 124x 127mm

700g / 1.54lb

-±25%

-30Vdc

0°C to +70°C

RDER NUMBERS

DC-UPS UB20.241 Standard DC-UPS unit

Accessory UZK24.071 Battery module 24V, 7Ah

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

ARKINGS

UZO24.071 UZK24.071 without batteries UZK24.121 Battery module 24V, 12Ah UZO24.121 UZK24.121 without batteries UZS24.100 Sensor & center tap board ZM2.WALL Panel/ wall-mount bracket ZM12.SIDE Side-mount bracket

Class I Div 2

IECEx ATEX

I.T.E.

II 3G Ex nA nC II T4 Gc

Marine

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UB20.241

-Series

NDEX

Page Page

1. Terminology and Abbreviations .........................3

2. Intended Use .......................................................4

3. Installation Notes ................................................4

4. Input / Output .....................................................6

5. Batteries and Battery Charging ........................ 10

6. Buffer Time ........................................................ 12

7. Ready and Buffering Relay Contact ................. 14

8. Replace Battery Relay Contact .......................... 14

9. Inhibit Input....................................................... 14

10. Efficiency and Power Losses.............................. 15

11. Lifetime Expectancy and MTBF ......................... 15

12. Functional Diagram ........................................... 16

13. Terminals and Wiring ........................................ 16

14. Front Side and User Elements ........................... 17

15. EMC .................................................................... 19

16. Environment ...................................................... 20

17. Protection Features ........................................... 21

18. Safety Features .................................................. 21

19. Dielectric Strength ............................................ 22

24V, 20A, DC-UPS

20. Approvals .......................................................... 22

21. Physical Dimensions and Weight ..................... 23

22. Accessories ........................................................ 24

22.1. ZM2.WALL – Wall-Mounting Bracket ...... 24

22.2. ZM12.SIDE – Wall-Mounting Bracket ...... 24

22.3. UZS24.100 – Sensor Board for DC-UPS ..... 24

22.4. UZK24.071 – 24V, 7AH Battery Module ... 25

22.5. UZK24.121 – 24V, 12AH Battery Module . 25

23. Application Notes ............................................. 26

23.1. Battery Replacement Intervals ................. 26

23.2. External Input Protection ......................... 28

23.3. Output Circuit Breakers ............................ 28

23.4. Back-feeding Loads .................................. 28

23.5. Parallel Use to Increase Output Current .. 29

23.6. Parallel Use for Redundancy .................... 29

23.7. Series Use for 48V Applications ............... 30

23.8. Using the Inhibit-Input ............................. 30

23.9. Troubleshooting ....................................... 31

The information presented in this document is believed to be accurate and reliable and may change without notice. No part of this document may be reproduced or utilized in any form without permission in writing from the publisher.

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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UB20.241

1. T

-Series

24V, 20A, DC-UPS

ERMINOLOGY AND ABBREVIATIONS

DC-UPS Abbreviation for Uninterruptible Power Supply system with a DC input and a DC output.

A DC-UPS utilizes batteries as back-up energy source.

Power supply mode Describes a condition where the input voltage is in the rated input voltage range and the

supplying power supply can deliver a sufficient amount of current for the DC-UPS and the load. Additionally it is assumed that the output is loaded within the allowed limits and the battery is charged, if necessary. The mode can also be called “Normal mode”.

Battery mode Describes a condition where the input voltage is below the transfer threshold level, the unit

is running on batteries (buffering) and the output is loaded within the allowed limits. The mode can also be called “Buffer mode”.

Normal mode see “Power supply mode”

Buffer mode see “Battery mode”

Inhibit mode Describes a condition where buffering is disabled on purpose (e.g. for service actions).

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

DC 24V A figure displayed with the AC or DC before the value represents a nominal voltage with

standard tolerances included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V).

24Vdc A figure with the unit (Vdc) at the end is a momentary figure without any additional

tolerances included.

may A key word indicating flexibility of choice with no implied preference.

shall A key word indicating a mandatory requirement.

should A key word indicating flexibility of choice with a strongly preferred implementation.

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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UB20.241

2. I

3. I

-Series

24V, 20A, DC-UPS

NTENDED USE

This device is designed for installation in an enclosure. Use an appropriate enclosure which protects against mechanical, electrical and fire hazards.

This device is intended for professional use in areas such as in industrial control, office, communication, and instrumentation equipment.

Do not use this device in equipment or systems where malfunction may cause severe personal injury or threaten human life.

NSTALLATION NOTES

This device may only be installed and put into operation by qualified personnel. The input must be powered from a SELV or PELV power source. Use DIN-rails according to EN 60715 with a height of 7.5 or 15mm. Mounting orientation must be output and input terminals on top. Do not obstruct air flow as the unit is convection cooled. Ventilation grid must be kept free of any obstructions. Use an appropriately sized 24V power supply, which can deliver the additional required internal current consumption

(including the charging current) specified as input current in the table of chapter 4. Install the batteries outside the cabinet or in a place, where the batteries will not be heated by adjacent equipment

and ensure sufficient ventilation for the batteries as required in the EN 50272-2 standard.

Use wires not smaller than 4mm batteries and the DC-UPS. Longer or thinner wires can change performance of the DC-UPS system.

Use a 35A fuse (ATOF The battery fuse protects the wires between the battery and the DC-UPS and shall be located close to the battery. If PULS battery modules are used, this fuse is already included.

Use a 4A fuse (ATOF point of the two 12V batteries and the “Center TAP” connection point of the DC-UPS. An equivalent protection is included on the PULS battery modules or the PULS UZS24 sensor board. Please note: 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 PULS battery modules (UZK24) and the PULS UZS24.100 sensor board.

The following installation clearances must be maintained when the device is loaded permanently with more than 50% of the rated power:

- Left / right: 5mm (15mm in case the adjacent device is a heat source)

- On top of the unit: 40mm

- On bottom of the unit: 20mm Agency approvals apply only for altitudes up to 2000m. Maximum surrounding air temperature: 70°C / 158°F. A disconnecting means shall be provided for the output and battery input when used in applications according to CSA

C22.2 No 107.1-01.

287 035 from Littelfuse or an UL listed fuse with the same characteristics) in the battery path.

287 004 from Littelfuse or an UL listed fuse with same characteristics) between the connection

(or AWG 12) and not longer than 2x1.5m (equal 1.5m cord length) between the

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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UB20.241

WARNI NG

24V Power

Supply

UB20.241

Input

+-+

24V Battery

Module

Buffered

Load

Non-

buffered

Load

24V buffered branches

24V Non-bufferd branches

Temp. Sensor

Output

Battery

Bat1

12V

Bat2

12V

Center Tap

Temp. Sensor

DC-UPS

Output

Input

N L PE

optional

UZK24

-Series

24V, 20A, DC-UPS

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

- Turn power off and disconnect the battery fuse before working on the device. Protect against inadvertent re-

powering.

- Make sure that the wiring is correct by following all local and national codes.

- Do not modify or repair the unit.

- Do not open the unit as dangerous voltages may be present inside.

- Use caution to prevent any foreign objects from entering the housing.

- Do not use in wet locations or in areas where moisture or condensation can be expected.

- Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns.

- Always dispose the batteries through a recycling organization. Batteries must be completely discharged before

recycling.

Fig. 3-1 Typical wiring diagram

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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UB20.241

4. I

Battery

Mode

Output

Voltage

Input

Voltage

Transfer Threshold

Power Supply

Mode

Power Supply

Mode

Temporarily

allowed No Charging, no Buf

fering

D: 26V C: 25V B: 24V

A: 22.5V

27V

26V

25V

23.5 V

30V30V30V30V

30V

18V

35V

Buffer Voltage Settings

Four Ranges:

26V25V24V22.5V

Normal

Operating

Voltage

(4 Ranges)

Buffer Voltage

Rated Input Voltage Range

Battery Mode

DCBA

Range A

Range B

Range C

Range D

-Series

24V, 20A, DC-UPS

NPUT / OUTPUT

The output is connected to the input through a back-fed protection (MOSFET). In power supply mode, the output voltage follows the input voltage decreased by a small voltage loss. In battery mode, the output voltage is a constant voltage, which can be preselected in one of four voltages.

Input Voltage Range: At voltages within the input voltage range, control functions such as LEDs, monitoring features, relay contacts, etc. are functioning normally. Within the input voltage range the unit can either be in power supply mode or in battery mode.

Normal Operating Voltage Ranges (four ranges):

The normal operating voltage range describes the input voltage, which supports the full functionality of the DC-UPS (including charging) but without entering the battery mode. It requires a minimum of 1V higher than the buffer voltage settings and a maximum voltage of not more than 30Vdc.

Buffering and Buffer Voltage:

Buffering will start immediately without interruption after the input voltage falls below the lower end of the normal operating voltage range. Buffering is possible even if the batteries are not fully charged. Buffering can not be started without having previously entered the normal operating voltage range. The buffer voltage is the output voltage determined by “the buffer voltage setting” and will not change as the batteries discharge. The buffer voltage is pre-selectable in one of four voltages.

Fig. 4-1 Definition of “power supply mode” and “battery mode”

ig. 4-3 Buffer voltage

Fig. 4-2 Input Voltag e Ranges

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

Settings on the front

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UB20.241

Input voltage

Normal operating ranges

Transfer voltage for switching into battery mode

Output voltage Ripple and

Requirements for supply on the input

Input current

-Series

nom. DC 24V range nom. 18-30Vdc Control functions such as LEDs, monitoring features,

input voltage

in power supply mode typ.

in battery mode nom.

noise voltage in power supply mode in battery mode max.

the power

internal consumption

total input current max. Sum of the output (load) current and the internal current consumption

Footnotes can be found on the next page.

24V, 20A, DC-UPS

-±25%

relay contacts, etc. are working. The unit can either be in power supply mode or in battery mode. See Fig. 4-2.

max. 30-35Vdc Temporarily allowed, no damage to the DC-UPS.

The red error LED will report “Input Voltage”, charging and buffering are not possible. See Fig. 4-2.

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

Ranges, where the unit does not switch to battery

mode. See Fig. 4-2. typ. typ. typ. typ.

typ. typ. typ. typ.

nom. nom. nom.

typ. 80mA When batteries are fully charged max.

max.

23.5 – 30Vdc 25 – 30Vdc 26 – 30Vdc 27 – 30Vdc

Range A for a 22.5V buffer voltage setting

Range B for a 24V buffer voltage setting

Range C for a 25V buffer voltage setting

Range D for a 26V buffer voltage setting

Please note: The lower end must be at least 1V higher

than buffer voltages settings.

23.5Vdc 25Vdc 26Vdc 27Vdc

0.12V less than input voltage at 20A

22.5Vdc

24.0Vdc

25.0Vdc

26.0Vdc

±3%

not applicable 120mVpp

Range A, 22.5V buffer voltage

Range B, 24V buffer voltage

Range C, 25V buffer voltage

Range D, 26V buffer voltage

The output voltage is always slightly lower than the

input voltage, independent of the value of the input

voltage. See Fig. 4-4 and Fig. 4-5.

The buffer voltage is the output voltage in battery

mode, selectable in four steps via rotary switch on the

front of the unit and will not change as the batteries

discharge. See Fig. 4-2.

better as the supplying power supply (filter included)

20Hz to 20MHz, 50Ohm

- Use an appropriately sized 24V power supply, which can deliver the additional required internal current consumption of the DC-UPS and the required current for charging the batteries. See also Fig. 4-6.

- Use power supplies that do not deliver more than 28A continuous output current

2.1A / 4.0A

For <10Ah / >10Ah settings; during battery charging, no temperature sensor installed

2.3A / 4.3A

For <10Ah / >10Ah settings; during battery charging, temperature sensor is installed

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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UB20.241

Output current

(dynamic peak current), see Fig. 4-9.

Overload behavior

Output short circuit current Return current

Allowed voltage between input and earth (chassis)

Capacitive and inductive lo

Input to Output Voltage Loss, typ.

0mV

10A

30mV

60mV

90mV

120mV

25A

20A

Output Current

150mV

A... 25°C B... 60°C

5A 15A

180mV

Power Supply

Voltage Loss UIN= U

OUT

Variable

Load, 0-25A

UB20.241

Input Output

-Series

24V, 20A, DC-UPS

in power supply mode

in battery mode

in power supply mode in battery mode

in power supply mode in battery mode typ.

nom. nom. nom.

nom.

typ.

25A 30A 20A at 22.5V, 18A at 26V 30A at 22.5V, 26A at 26V 80A

not limited

PLUS

Hiccup

Mode

not limited 31A for 2 sec

Continuously allowed For max. 5s Continuously allowed see Fig. 4-7 (interpolate linearly between 22.5V and 26V) For typ. 4s (BonusPower

® 4)

) see Fig. 4-7 (interpolate linearly between 22.5V and 26V) For typ. 25ms, output voltage stays above 20V,

Description see footnotes

and

Description see footnote 3)

Description see footnotes

and

50mOhm impedance, repetitive pulses, see Fig. 4-8.

typ. -200µA Leakage current to the input of the DC-UPS in battery

mode

max. 60Vdc or

42.4Vac

continuous, IEC 62103

ads No limitation

1) Use a 25A melting fuse with a melting I2t of 400A2s – 1500A2s 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.

2) The DC-UPS has no current limiting feature included in power supply mode. The current is limited by the supplying power supply or the fuse/ circuit breaker, which must be installed when the power supply has a continuous output current capability of more than 28A.

3) Hiccup

4) BonusPower

PLUS

Mode:

In battery mode, the DC-UPS can deliver 50% more output current for a period of up to 4s before it reduces the output current automatically to the nominal output current. If the current requirement is continuously higher than the nominal current, the current regulation of the DC-UPS reduces the output voltage. As soon as the output voltage falls below 18V, the output switches off and makes a restart attempt every 17s. This cycle is repeated as long as the overload exists.

The DC-UPS is designed to support loads with a higher short-term power requirement without damage or shutdown. In battery mode, the short-term duration is hardware controlled by an output power manager. At 150% output current, it is typically 4s and longer for lower currents. Once the BonusPower® time is exceeded, the maximum output current is automatically reduced to the nominal output current or the DC-UPS goes into the Hiccup

PLUS

mode.

ig. 4-4 Input to output voltage loss

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

Fig. 4-5 Input to output voltage loss

measurement setup

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UB20.241

Internal

current

consumption

Current

consumption

for battery

charging

Output Current

Input

Current

Output Voltage

0 20

28V

32A

124

16 24 28

Output Current

continuous

Hiccup

mode

for 4s

26V

22.5V

Output Current

31A

17s 17s

17s

Short circuit

Normal

load

Normal

load

Output Voltage (dynamic behavior, < 25ms)

28V

100A4020 60 80

10 30 50 70 90

26V

22.5V

Output Current

-Series

Fig. 4-6 Select an appropriate power supply,

which can deliver the additional current for

charging and internal consumption the DC-UPS

Fig. 4-8 Battery mod e: Hiccup

a short-circuit on output, typ.

PLUS

behavior during

24V, 20A, DC-UPS

Fig. 4-7 Battery mod e:

Output voltage vs. output current, typ.

Fig. 4-9 Battery mod e:

Dynamic peak current behavior, typ.

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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UB20.241

5. B

Setting of battery size selector Allowed battery sizes

Battery

Battery charging current

End

typ.

26.5V

center-tap not connected,

Temperature range for wh the charging process is enabled

-Series

24V, 20A, DC-UPS

ATTERIES AND BATTERY CHARGING

The battery is not included in the DC-UPS. Use one of the PULS 24V battery modules (see chapter 22.4 and 22.5). In addition to the PULS battery modules, the UB20.241 is also designed to be compatible with a large variety of different VRLA (Valve Regulated Lead Acid) or SLA (Sealed Lead Acid) batteries from various suppliers.

The battery is one of the most important parts of a DC-UPS system, which needs to be carefully selected while also paying close attention to storage, charging and environmental conditions. Select the proper size (capacity) according to the required buffer time (see chapter 6) and the lifetime requirements (see chapter 23.1).

Batteries are service parts and need to be replaced periodically or when the internal battery tests of the DC-UPS reports a random failure. Information regarding the DC-UPS battery tests and the replacement requirements can be found in chapter 23.1.

The wiring from the battery to the DC-UPS must follow the instructions in chapter 3. Be aware that the current from the battery to the DC-UPS can be higher than the load current due to the buffer voltage transformation, which restores the battery voltage to a constant buffer voltage.

The UB20.241 has a battery size selector included, which allows an optimal use of small and large battery sizes. It is not recommended to connect multiple batteries or battery modules in parallel. Chose larger sized battery instead.

Charging:

The UB20 comprises a constant current / constant voltage (CC-CV) charging method. When the center-tap connection is installed, both 12V batteries are charged individually with their own charger. The

center-tap connection is optional and if not installed, both batteries will be charged with one common charging voltage. The UB20 automatically recognizes if the center-tap connection is present or not.

When charging is approximately 85% completed, the individual green “Ready” LED for the specific battery stops flashing and is on solid.

During charging, the DC-UPS consumes additional current from the input. The supplying power supply must be able to deliver the additional required internal current consumption (including the charging current) specified as input current in the table of chapter 4.

When the temperature sensor is installed, the end-of-charge-voltage is temperature compensated. The UB20 automatically recognizes if a temperature sensor is connected or not. In case no temperature sensor is installed, the end-of-charge-voltage is fixed to a value which corresponds to a battery temperature of 40°C.

Use a PT1000 temperature sensor or the PULS UZK24 battery modules, which have this sensor already included. A list of suitable PT1000 temperature sensors from different vendors can be provided.

nom. 3.9Ah – 10Ah

small battery

< 10Ah

large battery

> 10Ah

10Ah – 150Ah

voltage nom. 24V 24V 2x 12V batteries in series

typ. 1.5A 3A In constant current mode

-of-charge-voltage typ. 2 x13.25V 2 x13.25V center-tap connected, no temperature sensor connected

no temperature sensor connected

typ. 2x 13.1 to 14.2V

2x 13.1 to 14.2V

center-tap connected,

temperature sensor connected

typ. 26.2V to 28.4V

26.2V to 28.4V

center-tap not connected,

temperature sensor connected

ich

nom. -10°C to +50°C

-40°C to +50°C

Footnotes can be found on the next page.

Aug. 2019 / Rev. 2.2 DS-UB20.241-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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