Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. +39 0522 345518 – Fax +39 0522 345551 – mail: [email protected]
www.adelsystem.com
Instruction Manual CBI2801224A rev5.doc
P
a
g
e
1
-
C
h
a
p
te
r:
A
ll
In
O
n
e
:
U
n
in
te
rr
u
p
ti
b
le
P
o
w
e
r
S
u
p
p
ly
O
u
tp
u
t
V
d
c
All In One: U
ninterruptible
P
ower
S
upply
Output Vdc
Thank you for having chosen one of our products for your work.
We are certain that it will give the utmost satisfaction and be a notable help on the job.
General Description
Thanks to the All In One units (DC-UPS), it will be possible to optimize power
management. The available power is automatically allocated between load and battery,
supplying power to the load is the first priority of the unit thus it is not necessary to double
the power, because also the power going to the battery will go to the load if the load so
requires. The maximum available current on the load output is 2 times the value of the
device rated current In. We call “Battery Care” the concept base on algorithms that
implement rapid and automatic charging, battery charge optimization during time, flat
batteries recovery and real time diagnostic during installation and operation. The Real Time Auto-diagnostic system,
monitoring battery faults such as, battery Sulfated, elements in short circuit, accidental reverse polarity connection,
disconnection of the battery, they can easily be detected and removed by help of Blink Code of Diagnosis Led;
during the installation and after sell. The continuous monitoring of battery efficiency, reduces battery damage risk
and allows a safe operation in permanent connection. Each device is suited for all battery types, by means of
jumpers it is possible setting predefined curves for Open Lead Acid, Sealed Lead Acid, Gel and Ni-Cd. They are
programmed for two charging levels, boost and charge, but they can be changed to single charging level by the user.
A rugged casing with bracket for DIN rail mounting provide IP20 protection degree. They are extremely compact and
cost-effective.
Main Characteristics
•
Input: Single-phase 115 – 230 – 277 Vac
•
Output Load: power supply:
24Vdc; 10 A
12Vdc; 15 A
•
Output Battery: charging
24Vdc; 10 A
12Vdc; 15 A
•
Modbus Connection
•
Suited for the following battery types: Open Lead Acid,
VRLA (AFM), Gel, and Ni-Cd.
•
Automatic diagnostic of battery status. Charging curve
IUoUO, constant voltage and constant current Battery Life
Test function (Battery Care)
•
Switching technology
•
Four charging levels: Boost, Absorption, Trickle and
Recovery
•
Protected against short circuit, Over Load and inverted
polarity
•
Signal output (contact free) for discharged or damaged
battery
•
Signal output (contact free) for mains or Back-UP
•
Protection degree IP20 - DIN rail; Space saving
Safety and warning notes
WARNING – Explosion Hazard Do not disconnect Equipment unless power has been switched off or the area is known
to be non-hazardous.
WARNING – Explosion Hazard. Substitution of components may impair suitability for class I, Division 2.
WARNING – Switch off the system before connecting the module. Never work on the machine when it is
live. The device must be installed in according with UL508. The device must have a suitable isolating facility
outside the power supply unit, via which can be switched to idle. Danger of fatal Injury!
Connection (terminal and wiring):
Cable Connection: The following cable cross-sections may be used:
Solid
(mm
2
)
Stranded
(mm
2
)
AWG
Torque (Nm)
Stripping
Length
1 Phase L N PE
Input AC
1 Phase L N PE
Input AC
In: 4.0
6.0
30 – 10 0.8 – 1.0 Nm
7 mm
Out: 4.0
6.0
30 – 10 0.8 – 1.0 Nm
7 mm
Signal: 0.2 – 2.5 0.2 – 2.5
24 – 14 0.5 – 0.6 Nm
7 mm
The connection is made by the screw type 2.5 mm
2
or 4.0 mm
2
terminal blocks. Use only copper cables that are
designed for operating temperatures of > 75 °C. Wiring terminal shall be marked to indicate the proper connection for
the power supply.
P
a
g
e
3
-
C
h
a
p
te
r:
O
p
e
ra
ti
n
g
a
n
d
D
is
p
la
y
E
le
m
e
n
t:
3
Output LOAD In Buffer Mode (Mains INPUT OFF)
Some example of buffering time depending on LOAD Output in function to the Ah of the battery.
Buffering Time
BATT1.2 Ah BATT 3 Ah
BATT7.2 Ah
BATT12 Ah
BATT100 Ah
Load 1.5 A
20 min
60 min
200 min
400 min
/
Load 3 A
8 min
30 min
120 min
240 min
/
Load 5 A
3 min
15 min
55 min
100 min
/
Load 7.5 A
2 min
10 min
30 min
60 min
/
Load 10 A
No
7 min
20 min
45 min
20 h
Load 12 A
No
3 min
12 min
30 min
600 min
Load 15 A
No
No
9 min
20 min
400 min
Load 20 A
No
No
7 min
13 min
240 min
Operating and Display Element:
No. 10: INPUT Mains AC Port pin L – N:
1 Phase Switching Power Supplies PE L N
No. 3: BATTERY Connection Port:
Connect the battery to the BATTERY (-) and (+)
One battery (12 Vdc) for 12V
Two battery (12 Vdc) connected in Series for 24V
No. 4: Output LOAD:
Connect this Output to the LOAD (-) and (+)
No. 1, 2 Signal Ports (output Isolated):
Connections for
No. 2: MAINS OR BACKUP: Input Mains On/Off. Contact: 5,6,7
No. 1: BATTERY FAULT Fault connections systems. Contact: 8,9,10
Relay Contact Rating:
Max.DC1: 30 Vdc 1 A; AC1: 60 Vac 1A : Resistive load (EN 60947-4-1)
Min.1mA at 5 Vdc: Min. permissive load
Signal Output port true table:
Port N°2
Led N°6 MAINS OR BACKUP
Port N°1
Led N°7 BATTERY FAULT
5-6 Closed
5-7 Closed
8-9 Closed OK
8-10 Closed
MAINS Input Vac
ON
■
- led off
■
- led off
OFF
■
- led On (1)
■
- led off
The BATTERY in
BACKUP it’s less than
30% cap?
YES
■
- led On
■
- led On
NO
■
- led On
■
- led off
BATTERY or system
FAULT?
YES
■
- led off
■
- led On (2)
NO
■
- led off
■
- led off
Note:
(1) For better efficiency of the system, filter relay MAINS OR BACKUP with a delay of at least 5 seconds before give
alarm Mains Lost, example: connection to PLC.
(2) See Diagnosis Led
5
6
7
8
2
19
13
14
11
12
10
3
4
9
16
15
17
18
1
P
a
g
e
2
-
C
h
a
p
te
r:
O
u
tp
u
t
P
o
w
e
r
c
o
n
n
e
c
ti
o
n
s
:
2
Output Power connections:
Normal connection
Typical application for All In One device, one output for LOAD
“DC Bus”, one Input/Output for connection to the battery.
N°1 battery (12 Vdc) for 12V;
N°2 battery (12 Vdc) connected in Series for 24V;
Parallel connection “Redundancy”
Power supplies can be paralleled for 1+1 redundancy to obtain a
higher system availability. Redundant systems require a certain
amount of extra power to support the load in case one power
supply unit fails. The simplest way is to put two CBI in parallel. In
case one power supply unit fails, the other one is automatically
able to support the load current without any interruption. This
simple way to build a redundant system has two major
disadvantages:
-
The faulty power supply can not be recognized.
- The Diagnosis LED will give the informations about the status
of the Load and the Battery (see Display Signals for more data).
It does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a -virtually
nearly impossible - case, the defective unit becomes a load for the other power supplies and the output voltage can
not be maintained any more. This can only be avoided by utilizing decoupling diodes which are included in the
Redundancy Module MR220. Recommendations for building redundant power systems: a) Use separate input fuses
for each CBI. b) Monitor the individual CBI units by three LED. Each unit has two relay: Mains or backup and Low
Battery or Battery Replacement (faulty situation). This feature reports a faulty unit; see Relay Contact Rating for any
technical detail. c) When possible, connect each power supply to different phases or circuits.
Serial connection:
a) It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed 150Vdc.
b) Voltages with a potential above 60Vdc are not SELV any more
and can be dangerous. Such voltages must be installed with a
protection against touching. c) For serial operation use power
supplies of the same type. d) Earthing of the output is required
when the sum of the output voltage is above 60Vdc. e) Keep an
installation clearance of 10 mm (left/right) between two power
supplies and avoid installing the power supplies on top of each
other. Note: Avoid return voltage (e.g. from a decelerating motor
or battery) which is applied to the output terminals.
Output Load (Mains INPUT ON)
The output LOAD in normal mode, Mains INPUT Vac Voltage present, follow the charging battery dc output voltage.
The minimum and maximum range stabilized are the following:
- Dip Switch selection 12V:11 – 14,4 Vdc; (Without battery connected out. Voltage fixed at 12Vdc)
- Dip Switch selection 24V:22 – 28.8 Vdc; (Without battery connected out. Voltage fixed at 24Vdc)
Thanks to the All In One units, it will be possible to manage the power. The available power, is automatically allocated
between load and battery: supplying power to the load is the first priority of the unit; thus it is not necessary to double
the power, and also the power available for the battery will go to the load if the load requires so:
in “Power Boost Mode” the maximum current on the load output is the 2 times the rated current 2 x In (I
load
= I
n
+ I
batt
) in
continuous operation is 3 times the rated current 3 x In (I
load
= 2I
n
+ I
batt
) for 4 seconds; after this parameter the devices
is electrically protected against overload and short circuit.
- In “Power Boost Mode”, if the current of the battery generate current to the load for a time more than 4 minutes and
Vbat<25V, the device give message (8 Blink), consequently means that the battery it is going to unloading.
- If the Mains Input Voltage fall below a Threshold level (50% of the Typ. Vac input) the battery it is immediately
connected to the Output Load, without any interruption.
- voltage dips: In this situation the voltage in the output load it is the same of the battery.
- To Avoid deep battery discharge, the battery will supply the load until battery voltage reaches 1.5 V/cell. Below
this level the device automatically switches off to prevent Deep discharge and battery damage.
P
a
g
e
4
-
C
h
a
p
te
r:
O
p
e
ra
ti
n
g
a
n
d
D
is
p
la
y
E
le
m
e
n
t:
4
Point of view
No. 6, 7 and 8 Display Signals
No.6: Led MAINS OR BACKUP: Input Mains On/Off
No.7: Led BATTERY FAULT (capacity less than 30%), Fault connections systems, Battery replacement.
No.8: Led DIAGNOSIS Battery charge mode, diagnosis of the system through “blinking code” signal.
Monitoring
Control
Chart:
State
LED Diagnosis
(No.8)
LED Battery
Fault (No.7)
Charging
Type
Trickle
1 Blink/2 sec
OFF
Absorption
1 Blink/sec
OFF
Boost
2 Blink/sec
OFF
Recovery
5 Blink/sec
OFF
Auto
diagnosis
of the
system
Reverse polarity or high battery Voltage (over 32.5Vdc for
24V)
1 Blink /pause
ON
Battery No connected
2 Blink/pause
ON
Element in Short Circuit
3 Blink/pause
ON
Over Load or short circuit on the load
4 Blink/pause
ON
Bad battery; Internal impedance Bad or Bad battery wire
connection.
5 Blink/pause
ON
Life test not possible
6 Blink/pause
ON
Bad thermal sensor
7 Blink/pause
ON
Boost condition; battery discharge after 4 min. of overload. 8 Blink/pause
ON
Internal fault or illegal configuration jumper
9 Blink/pause
ON
Low battery (under 18.5Vdc for 24V) Only if started from
battery, no Main input. Form Input N°12 or Push Bottom
10 Blink/pause
ON
MOD BUS error
11 Blink/pause
No. 9, 12: BATTERY START, No MAINS Vac
No. 9: Push-button, for 3 sec., in the front panel for switch ON the system without the “MAINS input Vac” but
only the battery connected.
No.12: It is also available the same function for remote Start from the battery, via RTCONN cable with 2
poles connector to put in Input N°12 and use with a Push button or a normaly open contact. Do not insert a
jumper in this position, penalty discharge completely the battery close to Zero in BACKUP.
No. 17: Battery Management Configurations
One device for all battery types.
Completely automatic, all devices are suitable to charge most
batteries types thank to User Selectable charging curves. They can
charge open lead acid, sealed lead acid, Gel and Ni-Cd batteries. It
is possible to change or add other charging curves connecting the
device to a portable PC.
Caution: Switch off the system before Setting the jumper.
For Battery Type Selection always refer to the data of the
manufacturer of the batteries.
Battery Type
Selection
Deep Switch Position
Trickle/Float
charge
(Volt/Cell)
Fast/Bulk charge
(Volt/Cell)
Open Lead
2.23
2.40
VRLA (AGM) “1”
2.25
2.40
Gel Battery “2”
2.30
2.40
Ni-Cd “3”
(1)
10% Imax Trimmer
1.70–(12V);1.5–(24V)
BATTERY TYPE
LIFE TEST
ENABLE POWER SUPPLY
BATTERY TYPE
BATTERY TYPE
BATTERY TYPE
BATTERY TYPE
