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Operator's manual
TruConvert DC series 1000, TruConvert System Control
Edition 2020-07-01
Document number A67-0140-00.BKen-001-05

Address for orders

TRUMPF Hüttinger GmbH + Co. KG
Technische Redaktion
Bötzinger Straße 80
D-79111 Freiburg
Fon: +49 761 8971 - 0
Fax: +49 761 8971 - 1150
Internet: http://www.trumpf-huettinger.com
E-Mail: [email protected]

For "partly completed machinery" in accordance with the EC
Machinery Directive, this document corresponds to the
assembly instructions.

Содержание TruConvert DC 1000 Series

Страница 1: ...Operator s manual TruConvert DC series 1000 TruConvert System Control TruConvert Modular...

Страница 2: ......

Страница 3: ...Operator s manual TruConvert DC series 1000 TruConvert System Control TruConvert Modular Original operator s manual Edition 2020 07 01...

Страница 4: ...1 05 Address for orders TRUMPF H ttinger GmbH Co KG Technische Redaktion B tzinger Stra e 80 D 79111 Freiburg Fon 49 761 8971 0 Fax 49 761 8971 1150 Internet http www trumpf huettinger com E Mail info...

Страница 5: ...ice depart ment The serial number can be found on the name plate of the device How to reach our Service department 49 761 8971 2170 49 761 8971 1178 Service Elektronik de trumpf com A67 0140 00 BKen 0...

Страница 6: ...II Good to know 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 7: ...3 1 3 Warning signs 1 3 2 Using the DC DC module 1 5 3 Authorized personnel 1 6 4 Warning signs on the DC DC module 1 7 5 What you must know as an operator 1 8 6 Dangers from high voltages 1 9 6 1 Pro...

Страница 8: ...7 What you must know as an operator 1 10 7 1 Ensuring safe operation of the DC DC mod ule 1 10 7 2 Check periodically 1 10 1 2 Safety 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 9: ...roduct specific docu mentation operating instructions manual etc must be adhered to throughout the entire product lifecycle 1 2 Storing the operating instructions These operating instructions contain...

Страница 10: ...dicates a potentially dangerous situation If it is not avoided injuries may occur NOTICE If such a situation is ignored material damage may result Description of the signal words Tab 1 1 1 4 Safety 20...

Страница 11: ...ersonal injury and loss of production The operator bears all risks The war ranty is rendered null and void Impermissible uses include for example Use of incorrect components Operation on voltages outs...

Страница 12: ...ks It is the duty and responsibility of the operator to maintain the qualifications of the authorized personnel The authorized per sonnel must therefore be trained at regular intervals The following a...

Страница 13: ...module 1 Read operating instructions 2 Dangerous voltage 3 Dangerous residual voltage 4 Dangerous battery voltage Warning signs on the DC DC module Fig 1 1 A67 0140 00 BKen 0 01 05 2020 07 01 Warning...

Страница 14: ...MPF to request new warning signs Warning sign Meaning This sign indicates that the operat ing instructions must be read Sign warns of hazardous voltage Sign warns of hazardous residual voltage Sign wa...

Страница 15: ...ening A person who comes into contact with live DC DC module parts may be killed or severely injured Simultaneous control via web based user interface and Modbus is possible Power transmission stopped...

Страница 16: ...module within the conditions descri bed in chapter Technical specifications 3 For the electrical connection use only cables that are in per fect condition and have the correct dimensions 7 2 Check per...

Страница 17: ...l fields of application 2 2 2 Function description 2 3 2 1 Operation 2 4 3 Construction 2 5 3 1 TruConvert DC series 1000 construction 2 5 3 2 TruConvert System Control construction 2 7 4 Display elem...

Страница 18: ...able battery systems The DC DC module may only be operated in combina tion with intrinsically safe batteries The batteries must be connected in accordance with the applicable local standards The relev...

Страница 19: ...speak of batteries in these operating instructions The DC DC module draws energy from a DC link and charges a battery The DC DC module draws energy from a battery and feeds it into a DC link The DC DC...

Страница 20: ...s the TruConvert System Control must be con nected upstream In the DC only configuration a TruCon vert System Control can control up to 16 DC DC modules see Fig 2 3 pg 2 4 1 PC with web browser or Mod...

Страница 21: ...sed metal housing The fan on the inside of the front panel draws in air for cooling All connecting elements are located on the back side 1 Front panel with mounting brackets 2 Display elements 3 Openi...

Страница 22: ...5 6 M6 threaded bolt for connecting the protective earth 7 Cover hood for battery connec tions 8 Threaded bolt minus for bat tery connection 9 Threaded bolt plus for battery connection 10 M6 thread fo...

Страница 23: ...et 2 3 Reset button reset IP address 4 No function 5 Display elements TruConvert System Control front side Fig 2 6 1 Connection of 24 V supply volt age 2 Threaded bolt for protective earth 3 RS 485 da...

Страница 24: ...g 2 8 Device condition LED Bootloader Initialize Alarm Idling Operation LED1 green on Flashing off Flashing Flashing LED2 yel low Flashing Flashing off off Energy direction Battery charging LED lights...

Страница 25: ...al specifications 1 TruConvert DC series 1000 data 3 2 2 TruConvert System Control data 3 8 3 Technical data dependent on device var iant overview 3 10 A67 0140 00 BKen 0 01 05 2020 07 01 Technical sp...

Страница 26: ...llowing dimensioning of the rated fuse current IFuse IRated x 1 56 36 A x 1 56 56 16 A The permissible operating voltage of the fuse must be higher than the DC link voltage Fuse ratings UOperation 100...

Страница 27: ...plies for the entire range Measuring accuracies Tab 3 3 Description Value Maximum efficiency 97 4 CEC efficiency at 48 V and 800 V Self supply not taken into consid eration 96 7 Efficiency Tab 3 4 Des...

Страница 28: ...l life span 10 years Life span Tab 3 6 Description Connection Battery connection plus M8 threaded bolt minus M10 threaded bolt DC link DC Link PCB plug connector 3 pin IPC 16 3 STF 10 16 1969467 from...

Страница 29: ...tion Value Dimensions W x H x D incl connection components 216 mm x 132 mm x 515 mm 8 5 x 5 2 x 20 3 Dimensions W x H x D without connection components 216 mm x 132 mm x 456 mm 8 5 x 5 2 x 18 Weight 1...

Страница 30: ...ation Dimensional drawing Fig 3 3 Description Value Sound emission level Distance of 1 m from DC DC mod ule 70 dB A Sound emissions Tab 3 9 3 6 TruConvert DC series 1000 data 2020 07 01 A67 0140 00 BK...

Страница 31: ...Rated operation TruConvert DC 1010 5 C to 30 C 23 F to 86 F Limited power operation TruConvert DC 1008 40 C to 65 C 104 F to 149 F Limited power operation TruConvert DC 1010 30 C to 65 C 86 F to 149...

Страница 32: ...TruCon vert AC 3025 or TruCon vert DC series 1000 RJ 45 Reset button Resetting the IP address Display 3 status LEDs TruConvert System Control interfaces Tab 3 11 Description Value Dimensions W x H x...

Страница 33: ...to 65 C 23 F to 149 C 5 90 Up to approx 78 kPa 2000 m high above sea level Pollution degree 2 Storage 20 C to 80 C 4 F to 176 F 5 90 Trans port 20 C to 80 C 4 F to 176 F 90 Environmental conditions T...

Страница 34: ...209 A Brief overload while charging discharging for 1 min 1 2 12 kW max 250 A Battery connection maximum values Tab 3 14 1 Certificate mark 2 Material number Name plate of 2582407 DC DC module CSA ma...

Страница 35: ...while charging discharging for 10 min 1 2 Brief overload while charging discharging for 1 min 1 2 Battery connection maximum values Tab 3 15 A67 0140 00 BKen 0 01 05 2020 07 01 Technical data dependen...

Страница 36: ...3 12 Technical data dependent on device variant overview 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 37: ...oltage 24 V DC TruCon vert DC series 1000 4 5 3 DC link TruConvert DC series 1000 4 6 4 Battery connection TruConvert DC series 1000 4 7 5 Data input data output IN OUT TruCon vert DC series 1000 4 8...

Страница 38: ...7 Ethernet 4 10 8 RS 485 4 11 4 2 Interfaces 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 39: ...tective earth connection Protective earth connections Fig 4 1 On the rear side of the housing M6 internal thread On the cover hood M6 threaded bolt The cross section of the protective earth is depende...

Страница 40: ...Fig 4 3 4 4 Protective earth TruConvert DC series 1000 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 41: ...must be performed by the customer Supply voltage 24 V DC Fig 4 4 At the DC DC module Phoenix PCB plug connector Required counterpart connector 2 pin 8A CS 3 5 mm Connector for 24 V DC Fig 4 5 External...

Страница 42: ...10 16 mm Connector for DC link voltage Fig 4 7 2 x 2 5 mm2 2 x AWG 13 The insulation must exhibit sufficient electric strength Note To keep inductivity at a minimum cables should be twisted All pole...

Страница 43: ...ted All pole max 350 A The customer must install suitable separation devices into the connection between the DC DC module and battery The separation devices must comply with applicable standards Indiv...

Страница 44: ...ons IN OUT Fig 4 10 RJ 45 male connector Twisted pair patch cable in accordance with standard TIA EIA 568A B CAT 5 or higher Max length 100 m 4 8 Data input data output IN OUT TruConvert DC series 100...

Страница 45: ...the customer as close to the housing as possible 24 V supply voltage DC Fig 4 11 Connector for 24 V supply voltage DC Fig 4 12 On the device Phoenix PCB plug connector Required counterpart connector...

Страница 46: ...air patch cable in accordance with standard TIA EIA 568A B CAT 5 or higher Max length 100 m Note The total length of the data cable must not exceed 30 m from the PC to the last system control 4 10 Eth...

Страница 47: ...onnection Fig 4 14 RJ 45 male connector Twisted pair patch cable in accordance with standard TIA EIA 568A B CAT 5 or higher Max length 30 m A67 0140 00 BKen 0 01 05 2020 07 01 RS 485 4 11 View Connect...

Страница 48: ...4 12 RS 485 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 49: ...ation 5 2 2 EU declaration of conformity TruCon vert DC 1008 5 3 3 EU declaration of conformity TruCon vert System Control 5 4 4 CSA certification 5 5 4 1 Location of the CSA mark 5 5 A67 0140 00 BKen...

Страница 50: ...ectives Low voltage directive 2014 35 EU Electromagnetic compatibility directive 2014 30 EU Standards taken into account EN 62040 2 2006 AC 2006 EN 62109 1 2010 UL 1741 5 2 CE certification 2020 07 01...

Страница 51: ...pply lines of the 24 V supply voltage are equipped with the provided ferrite cores Otherwise class C2 is achieved EU declaration of conformity TruConvert DC 1008 material number 2400760 Fig 5 1 A67 01...

Страница 52: ...y lines of the 24 V supply voltage are equipped with the provided ferrite cores Otherwise class C2 is achieved EU declaration of conformity TruConvert System Control material number 2418064 Fig 5 2 5...

Страница 53: ...C22 2 No 107 1 16 UL 1741 Second Edition IEC62109 1 First Edition National Differences UL62109 1 IEC 62109 1 2010 EN 62109 1 2010 4 1 Location of the CSA mark If the name plate of the device bears th...

Страница 54: ...5 6 CSA certification 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 55: ...ng the delivery 6 3 2 Unpacking 6 4 2 1 Disposing of packaging material 6 4 3 Transport storage 6 5 3 1 Transport 6 5 3 2 Storage conditions 6 5 4 Requirements for the site 6 6 5 Possible installation...

Страница 56: ...6 8 6 2 Connection diagram with 3 DC DC modules example 6 11 7 Dismantling 6 12 7 1 Dismantling the DC DC module 6 12 8 Shipping 6 13 8 1 Shipping the module 6 13 9 Disposal 6 14 9 1 Disposing of the...

Страница 57: ...mpleteness in accordance with the delivery note and also for visible damages incurred during transport 2 In order to retain the right of recourse report any shipping damages immediately in writing to...

Страница 58: ...aterial If you do not want to keep the packaging material for a subse quent transport Dispose of all packaging materials in compliance with the rel evant regional waste disposal regulations 6 4 Unpack...

Страница 59: ...TRUMPF 2 Maintain specified environmental conditions 3 2 Storage conditions If you do not install the module immediately following delivery 1 Store the module in original packaging If the original pa...

Страница 60: ...at the air flow rate must be multiplied by the number of devices if several modules are operated Air short circuits and mutual interference of the modules must be prevented Number of modules Air flow...

Страница 61: ...on is only permitted under the follow ing conditions The cooling air moves in the upwards direction Installation of a collection tray under the DC DC module The collection tray must prevent any glowin...

Страница 62: ...Fuse the battery connection with max 350 ADC at all poles Fuse the DC link with max 20 ADC at all poles Interchanged polarity destroys DC DC modules Maintain polarity Abrupt connection of the DC link...

Страница 63: ...e 8 Nm 2 Screw protective earth to the threaded bolt on the cover hood Max torque 8 Nm 3 Screw protective earth on TruConvert System Control Max torque 2 Nm 4 Fully discharge the battery and ensure ab...

Страница 64: ...tput of the DC DC module to the IN data input of the next DC DC module Connect the terminating resistor to the OUT data out put of the last DC DC module 13 Connect the TruConvert System Control to the...

Страница 65: ...minating resistor Connection diagram example with 3 DC DC modules Fig 6 5 Note The terminating resistor must be connected to the last bus par ticipant to ensure data transmission The terminating resis...

Страница 66: ...ttery cannot be discharged open separators on the battery 2 De energize the connection cables to the DC link voltage 3 De energize the connection cables to the 24 V supply volt age 4 Unscrew connectio...

Страница 67: ...se packaging material which can withstand transport stresses to ship the module If the original packaging is no longer available Suitable packaging material can be purchased from TRUMPF A67 0140 00 BK...

Страница 68: ...9 Disposal 9 1 Disposing of the module Observe the local regulations when disposing of the module 6 14 Disposal 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 69: ...r interface 7 9 2 1 Calling up the web based user interface 7 9 2 2 Menu structure 7 10 3 Operation via Modbus 7 11 3 1 Establishing a connection 7 11 3 2 Modbus Register Map 7 11 4 Transmission of po...

Страница 70: ...alues 7 26 8 1 Set process set values 7 26 9 Data backup 7 28 9 1 Saving data 7 28 10 System configuration 7 29 10 1 Setting the system configuration 7 29 11 System control 7 32 11 1 Setting the syste...

Страница 71: ...e same address range on the PC as on the TruCon vert System Control 192 168 1 3 On the PC set the last block of the IP address Do not set the same address as on the TruConvert Sys tem Control IP addre...

Страница 72: ...resent system configu ration 0 No configuration This configuration only occurs in the event of an error e g if there is no connection to the modules check cables or if an incorrect module type was det...

Страница 73: ...splayed If the set system configuration Expected Configuration dif fers from the automatically detected system configuration Detected Configuration the initial commissioning screen is displayed again...

Страница 74: ...C module in the DC Volt age Alarm Thresholds area Minimum Battery Voltage Threshold V lower limit up to which the battery is discharged If this value is not met e g due to short circuit of the battery...

Страница 75: ...VCC curve Fig 7 4 20 Check the device status in the upper left corner of the user interface Device status Idle Idle The device is ready for use Device status Error Power Up Error The device is not re...

Страница 76: ...tage bit enter 1 Press key The status changes from Idle to Operation The status LEDs on the AC DC module and system control light up orange The contactor connects the mains 25 To stop the transmission...

Страница 77: ...on the PC 3 Enter IP address of the TruConvert System Control in the address line IP address of the TruConvert System Control on delivery 192 168 1 2 1 Display of the current device status 2 Main oper...

Страница 78: ...ansmission of power on off pg 7 16 see User interface displaying and resetting mes sages pg 7 18 see Display actual values pg 7 24 DC DC module settings see Operating with overload pg 7 22 see Set pro...

Страница 79: ...on Condition Initial commissioning was performed see Commissioning pg 7 3 1 Connect the TruConvert System Control to the Modbus mas ter with an Ethernet cable 2 To switch on the system control and the...

Страница 80: ...rs to factory settings bit 0 0 1 UIN T16 Coil 1 01 05 1016 Timeout for com munication s 1 0 10 1 UIN T16 Regi ster 1 03 06 1017 Setting this flag will restart the CPU only in Idle or Error State 0 0 1...

Страница 81: ...100 UIN T16 Regi ster 1 04 Alarm and warning messages Tab 7 5 Process set values Addr Lengt h Data type F Code read F Code write Description Unit Reso lution Defaul t Min max 4000 1 coil UINT 16 01 05...

Страница 82: ...ase W 1 0 8000 0 1200 0 4124 1 reg UINT 16 03 06 Max battery voltage alarm limit V 0 1 750 0 750 4127 1 reg UINT 16 03 06 Min battery voltage alarm limit V 0 1 0 0 700 4500 1 reg INT 16 03 06 Battery...

Страница 83: ...rrent 8 Max battery voltage 16 Min battery voltage multi mode display possible 1 5126 1 reg 04 Overload capacity 0 1 5127 1 reg 04 DC link voltage V 1 0 5300 32 reg STRIN G 03 Status of the limiting c...

Страница 84: ...slave to be addressed see Tab 7 6 pg 7 14 Note User interface and Modbus have different scaling For example 100 A ms 100 on user interface 10000 in Modbus 2 Enter set value for the battery current in...

Страница 85: ...stopping power transmission for other DC DC mod ules Select another DC DC module via user interface or slave address via Modbus and perform the previous steps again or To switch on all DC DC modules s...

Страница 86: ...3 Save messages as list 4 Alarm and warning messages 5 Display hide messages by type Sidebar expanded Fig 7 8 A message consists of 3 components Code message number Source originator and message text...

Страница 87: ...idebar click on the icon to display the messages 4 Press Reset The icon turns white again All messages are reset 5 Hide messages To hide the window of the sidebar click on the active icon again 1 Icon...

Страница 88: ...7 13 Slave address 0 The number of all messages that occurred in the system is output 2 Read out the number of current alarm warning info mes sages that have occurred on an individual DC DC module Sl...

Страница 89: ...m and were caused by the respective DC DC module The address represents the message num ber that was stored there in the overview list slave address 0 The value stored at this address can be 0 or 1 Va...

Страница 90: ...is regulated accordingly by the system Note Overload operation is only possible in the overload temperature range from 5 C to 40 C and with a battery voltage 30 V 1 To select the same settings for all...

Страница 91: ...oad capacity increases again and overload operation is possible again 6 2 Examples Reduce and then again increase overload capacity The overload capacity drops from 100 to 0 if the system is operated...

Страница 92: ...the current battery values User interface Select Operation Device Control DC DC Read the actual values in the Status Battery Interface area Modbus Read actual values see Tab 7 7 pg 7 15 3 Display cur...

Страница 93: ...er interface Select Operation Device Control DC DC Read the actual value in the Device Temperature area Modbus Read actual value see Tab 7 7 pg 7 15 A67 0140 00 BKen 0 01 05 2020 07 01 Actual values 7...

Страница 94: ...ery is charged Modbus see Tab 7 6 pg 7 14 3 Set the lower and upper alarm limit User interface Enter the limit values for the DC DC module in the DC Voltage Error Thresholds area For DC Voltage Limits...

Страница 95: ...ee Fig 3 1 pg 3 4 User interface Set the following in the Voltage Current Characteristics VCC Settings area VCC Start Point Current A battery current at mini mum battery voltage VCC End Point Current...

Страница 96: ...in the TruConvert System Control 3 In the Save settings area select Restore factory settings to again restore the factory settings 4 Press Export settings to save the current settings as a CSV file on...

Страница 97: ...igura tion is displayed as the sug gested value 2 Most recently saved configura tion 3 Most recently saved configura tion does not match the detected configuration Input screen System Configuration Fi...

Страница 98: ...DC and DC DC modules are connected to the sys tem control 3 To save the selection press Save selection 4 To restart the TruConvert System Control press Restart CPU 1 Display of the current device stat...

Страница 99: ...displayed If the set system configuration Expected configuration dif fers from the automatically detected system configuration Detected configuration the input screen System configu ration is display...

Страница 100: ...e see Tab 7 3 pg 7 12 11 2 Changing network settings Note The IP address can only be changed via the user interface 1 Select CONFIGURATION Server Configuration 2 Enter new values in IP Adresse IP addr...

Страница 101: ...n to restart the system The IP address of the TruConvert System Control is reset to 192 168 1 2 7 To change the network settings User interface Enter new values for IP Subnet Mask IP Host and IP Gatew...

Страница 102: ...th new software stored on PC 1 Select SW update 2 In the Software update area press the button and open the zip file 3 Press the button to upload the zip file If the update was performed successfully...

Страница 103: ...Package area read the details on the installed software package Relevant details are Integration Level and Buildnumber 5 The software version on the system control can be read in the Software System...

Страница 104: ...1 in frequently needed areas 2 To display the created favorites page click on the star at the top in the menu bar 3 1 Click the prohibition symbol to delete area from the favor ites 2 Click arrow to m...

Страница 105: ...isplay search field 2 Enter keyword 3 Result of the search Search Fig 7 18 1 Click on the magnifying glass at the top in the menu bar 1 2 Enter the keyword in the search field 2 Press key All areas th...

Страница 106: ...16 State diagram State machine Fig 7 19 7 38 State diagram 2020 07 01 A67 0140 00 BKen 0 01 05...

Страница 107: ...enance 1 Maintenance work 8 2 1 1 Periodic check of the environmental condi tions 8 2 1 2 Exchanging fans 8 2 1 3 Performing software updates 8 2 1 4 Cleaning 8 2 A67 0140 00 BKen 0 01 05 2020 07 01 M...

Страница 108: ...ssible 1 2 Exchanging fans The operating hours of the fan are counted After the allowed running period is up the module outputs a message TRUMPF recommends replacing the ventilator after an operation...

Страница 109: ...Chapter 9 Troubleshooting 1 Fault indication and messages 9 2 1 1 Fault indication with the LEDs 9 2 2 Messages 9 3 A67 0140 00 BKen 0 01 05 2020 07 01 Troubleshooting 9 1...

Страница 110: ...nterface Via the Modbus 1 1 Fault indication with the LEDs 1 Front side TruCon vert DC series 1000 2 Rear side TruCon vert DC series 1000 3 TruConvert System Control front side Status LEDs Fig 9 1 LED...

Страница 111: ...ting the device with the web based user interface the alarm and warning numbers are displayed together with the message text In case of control with Modbus only the numbers and no text are transmitted...

Страница 112: ...upply undervoltage DC DC module 60145 Wrong polarity on DC terminal detected DC DC module 60132 RS485 communication alarm DC DC module 60129 Battery voltage under threshold setting DC DC module 60150...

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