DIN Rail UPS Model: DIN-UPS Installation/Operation Manual

Transcription

1 DIN Rail US odel: DIN-US 12-5 Installation/peration anual Table of Contents Section age Section age Quick Start 2 1) General Information 4 aterials rovided 4 ptional ccessories 4 2) Safety Information 4 ) Installation/Wiring 4 ) ounting 4 ) Wiring 5 1. Input 5 2. utput 5 C) Form C Contact 5 D) Temperature Compensation Sensor 6 4) Settings 6 ) attery Type/Charge Curve 6 ) Time Charge Current Limit/attery 7 Charge Level C) Time uffering/attery Run Time 8 D) System Setttings 8 5) peration 8 ) attery Start w/o resent 8 ush utton ) Status Indicator LD s 8 C) LVD 9 6) rotection 9 7) Specifications 1 8) Troubleshooting 11 9) Warranty DINUS125 S F hone:

2 Figure 1: Quick Start Quick Start Guide Ga Gb H F I J 1) 2) ) K D C a b c j1 j2 ) Input: Wire Input lock (lettered left to right) a) arth Ground b) Hot 2 V: no jumper installed across j1 & j2 Hot 115 V: wire jumper across j1 and j2 c) Neutral j1 & j2) Jumper these two inputs for 115 V operation See page 5 for details. ) attery utput: two terminals each for plus and minus. Utilize dual wiring when battery location is more than 15 feet from unit. See page 5 for details. C) attery Charge Current Limit: llows setting maximum current flow to battery during recharge cycle, use when low amp-hour batteries are applied to system to prevent overheating when recovering dead batteries. djustment range 2-1% of available charge current. (vailable charge current = unit output rating of 1 amps - load demand. Note: the unit has a load priority circuit, all produced power is made available to the load, remaining power is available for battery charging). See page 6 for details. ounting DIN DC USto DIN Rail D) attery Temperature Sensor (optional): lug in port (RJ-45). See page 6 for details. ) Communication odbus: contact factory for more information F) utput to Load, two terminals each for plus and minus, utilize dual wiring when load is more than 15 feet from unit. Note: the unit has a load priority circuit, all produced power is made available to the load, remaining power is available for battery charging. See page 5 for details. G) Form C Contacts: ctivate upon: a. power fail b. Low battery or poor battery condition See page 5 for details. H) System Settings: via plug-in jumper programing terminals located on top of the unit. a. Install jumper per illustration below (Table 1) to: i. Select fl oat voltage per attery Type and enable bsorption Charge (see page page 7 for details) ii. nable attery Test (Functional Setting) iii. Disable/nable Load riority (Functional Setting) See page 8 for details on functional settings. Removing DIN DC US from DIN Rail Insert screwdriver in slot of bottom tab and twist to extend bracket 2 hone:

3 I) Time uffering/attery Run Time Settings: dial in time interval of desired run time of battery without disconnect. a. 1-6 minutes or b. Set at zero for battery run until LVD 1.5 VDC (1.75 VC) See page 7 for details. J) attery Start w/o resent ush utton: a. If system shuts down due to loss of and battery, power push button will allow battery to reconnect and supply the load if sufficient battery voltage is present. K) Status Indicator LD s 1. Fail: perating on battery back-up power (LD n). LD extinguishes when is present. 2. Low battery, or poor battery condition. Charger utput Status and Fault ode Diagnosis: by blink code: Table 1: System Settings: attery Selection/bsorption Charge Note: voltages above are at 2 C with no battery temp. sensor connected. Charge Status link Code: ulk: 5 blink/second - Recovery bsorption: 2 blink/second - ulk Float: 1 blink/second Fault ode Diagnosis link Code: Reverse olarity: 1 blink, pause attery Not Connected: 2 blink, pause verload or Short Circuit: 4 blink, pause ad attery Wire Connection, or ad attery (internal impedance): 5 blink, pause ad Thermal Sensor: 7 blink, pause and diagnostic See page 8 for details. attery Type Selection Float Charge/ Jumper Insert osition bsorption Charge naable/ Jumper Insert osition pen Lead (Default) None 1. VDC os. 6 Sealed Lead Insert Jumper: os. 1 os. 1 os VDC Gel attery Insert Jumper: os. 2 os. 2 os VDC hone:

4 Table 2: System Settings: Functional Settings Function Setting attery Test N Insert Jumper: os os. 4 Insert jumper at position 4 to enable eriodic attery condition test process. (Fault reported by LD diagnosis blink code, see Table 6): attery wiring connection attery efficiency/sulfation (impedance tesst) Shorted Cell Jumper inserted into position 7 making all power from the unit available for battery charging by disabling the load priority output function. Under low battery charge condition, output voltage to load will be equal to that of the battery voltage, thus useful voltage to the load will not be available until the battery recovers to proper levels. Load riority Disable (akes full power available for charging) Insert Jumper: os os. 7 1) General Information This DIN rail mount DC US Combines all system power functions: power supply, battery charger, US circuitry and status monitoring in one compact unit that produces 12 volt, 5 amps allocated via dual outputs for load and battery: Load output: load priority distribution ensures power is dedicated fi rst to the load, with remainder then allocated to battery charging, thus preventing a discharged battery from impacting operation of critical loads. attery output: step charging for rapid battery recovery, programmable for battery type, with optional temperature compensation sensor attery automatically on line to support load anytime fails Low voltage disconnect protects battery from total discharge utomatic periodic battery health diagnosis High operating temperature range to 7 C larm contacts: fail, battery status/condition aterials rovided: 1 ea. DIN-US unit with integral DIN rail mount clip 4 ea. Jumper tabs for programming 1 ea. Jumper wire (orange) for 115 volt input operation ptional quipment: Temperature Compensation Sensor, /N: ) Safety Information WRNING xplosion Hazard. Do not disconnect loads or battery unless input and battery have been switched off. WRNING xplosion Hazard. Substitution of components may impair suitability for class I, Division 2. WRNING Switch off or remove input and battery power before wiring the DIN-US Never work on the DIN US when it is connected to input and battery. The DIN US must be installed in accordance with UL58 or local electrical codes depending upon the application. The DIN US should have a suitability sized input circuit breaker feeding its input. See specification section for maximum input draw for your input voltage for circuit breaker sizing. CUTIN: Hot surface. void touching the DIN US case while operating at or near its full load capacity. Remove and battery power and allow DIN US at least 1 minutes to cool before removing from DIN Rail. ) Installation/Wiring ) ounting: The unit is designed for 5 mm DIN rail mounting in an enclosure and relies on convection (free air) cooling, thus must have a minimum vertical and horizontal distance to adjacent surface of 4 (1 cm) to this power supply in order to assure suffi cient air flow. Note, that depending on the ambient temperature and load of the device, the temperature of the case can become hot to the touch. The unit is designed for vertical mount (+/- 5 ) and has an integral clip on the back to secure it to the rail. To mount, place the top tabs over the top of the DIN rail, and using a long slotted screw driver insert it in the groove at the bottom of the bracket and twist which will extend the spring loaded mounting bracket downward allowing the unit to be positioned against the DIN rail, release the bracket with DIN US positioned vertically and the rail will be captured and the unit secured. 4 hone:

5 6 6 Figure 2: ounting Figure : Removing SLCTIN LW R TI UFFRING Insert screwdriver in slot of bottom tab and twist to extend bracket ) Wiring 1. Input: Terminal lock (lettered left to right) - Figure 4 a) arth Ground b) Hot (note: install jumper provided across terminals j1 and j2 for 115 V input) c) Neutral j1 & j2) Jumper these two terminals for 115 V operation and apply 115V hot to term b and neutral to c Recommended wire size: 16 WG Insert screwdriver in LW R slot of bottom tab and twist to extend bracket STRT i DIGNSIS IN TTR Figure 4: Input Terminal lock CHRGING DIN-US 12-5 INUT: 115-2Vac UTUT: 12Vdc 5 INUT L N JUR FR 2. utput The unit has dual output circuits: one for connection to the Load, the other to the back-up battery. Note: the unit has a load priority circuit, all produced power first is made available to the load with remaining power made available for battery charging. oth outputs are isolated from the case. a b c j1 j2 range Jumper Wire (provided) attery utput: two sets of terminals each for plus and minus. Utilize dual wiring when battery location is more than 15 feet from unit to minimize voltage drop. See page 2 and, Section H for programming per battery type. utput to Load: two terminals each for plus and minus, utilize dual wiring when load is more than 15 feet from unit to minimize voltage drop. Fuse note: We recommend a 5 amp fuse be installed on the hot leg at battery. If using both sets of battery terminals on DIN US (i.e. two pairs of wires, recommended for long wire runs), connect both hot wires to one side of battery fuse. attery/utput wires size (recommended): 1 WG Terminal lock maximum wire size (recommended): 1 WG C) larm Contacts, Form C (Isolated): Form C Contacts for remote monitor: ctivate upon: a. power fail b. Low battery, or poor battery condition SLCTIN TI UFFRING STRT DIN-US 12-5 INUT: 115-2Vac UTUT: 12Vdc 5 Figure 5: utput Terminals Load utput i LW R LW R DIGNSIS attery utput IN X CHRGING LVL (1) (2) UTUT LD INUT JUR FR TTRY L N () (4) T R C D U S U X (714) techservice@newmarpower.com C US 5 hone:

6 6 6 6 Table 2: larm Contacts Contact Input Fail LD The sensor will vary the battery charging voltage depending on the battery s temperature and charge program setting. Table : bsorption Charge Voltage & Float Charge Voltage Settings 2 Fault attery* LD Diagnosis LD Figure 6: larm Contacts Terminals, Form C (Isolated) only closed open open closed off on 2 link-ause att closed open closed open off off 1 link/sec SLCTIN att only open closed closed open on off off LW Low att open closed open closed on on off R 9 1 * Labeled Low attery or attery Replacement on Front anel SLCTIN Relay Contact Rating: Figure 7 & TI 1: Status Indicator LDs UFFRING ax. DC: VDC, 1 amp; : 6 V, 1 amp: Resistive load (N ) LW R in.1m at 5 VDC LW 1 R T D) ptional attery Temperature Compensation Sensor /N: TI UFFRING To install, remove the access tab in the front panel decal labeled STRT i DIGNSIS R LW IN X Temp robe, install the Temp. Sensor into the RJ-45 connector. ttach 2 R sensor to side of battery using RTV silicone. CHRGING LVL DIN-US STRT 12-5 INUT: 115-2Vac UTUT: 12Vdc 5 DIN-US 12-5 INUT: UTUT: INUT 115-2Vac JUR FR 12Vdc 5 Figure 8: attery Temperature Sensor ccess LTab N i DIGNSIS IN X CHRGING LVL T U R SLCTIN ccess Tab INUT L LW R N JUR FR (1) (2) UTUT LD 6 Formula for determining temperature compensated Float or bsorption voltage based on battery temperature: Float Formula: Float Voltage = (1. * VDC ) (sensor temp. 2 C) (.18 VDC) * see Table 1 for Float voltage based on battery type selected TI UFFRING xample Conditions attery selection jumper installed for 1.4 VDC Sealed Lead Float voltage attery temperature = 6 C INUT Float voltage = (1.4 VDC) (6 C 2 C) (.18 VDC) = (1.4 VDC) (4 C x.18 VDC) = 1.4 VDC.72 VDC = VDC 6 C JUR FR TTRY L N () (4) If the battery temperature is less than -2 C or greater than +6 C, an outside its range (temp. sensor) alarm is signalled with code 7 blink. If the sensor is not connected or if the sensor is defective, the LD Low att will illuminate and the LD Diagnosis LD continues to show the status of the battery, i.e., trickle charge, fast charge or recovery charge. STRT DIN-US 12-5 INUT: 115-2Vac UTUT: 12Vdc 5 i LW R DIGNSIS IN X CHRGING LVL T R C D U S U X (714) techservice@newmarpower.com C US hone:

7 6 4) Settings Figure 9: attery Type ) attery Type/Charge Curve Charge curve per battery type: via programing jumpers on top panel of unit left side. Insert jumper tabs for battery selection Using programming jumper tabs provided and a small needle nose pliers, insert programming jumpers to select float voltage and enable absorption voltage per per battery type. Caution do not program unit while connected to power. SLCTIN LW R R Table 4: attery Selection/bsorption Charge TI UFFRING F attery Type Selection pen Lead (Default) Float Charge/ Jumper Insert osition bsorption Charge naable/ Jumper Insert osition None os. 6 STRT i L R R DI Sealed Lead Insert Jumper: os VDC os. 1 os. 6 DIN-US 12-5 INUT: 115-2Vac UTUT: 12Vdc 5 Gel attery Insert Jumper: os VDC os. 2 os. 6 INUT L N JUR FR 1.7 VDC ) attery Charge Current Limit/attery Charge Level llows setting maximum current fl ow to battery during recharge cycle- use when low amp-hour batteries are applied to system to prevent overheating when recovering dead batteries. djustment range 2-1% of available charge current. (vailable charge current = unit output rating of 1 amps minus load demand. Note: the unit has a load priority circuit, all produced power is made available to the load, remaining power is available for battery charging). To set, use small slotted screw driver to rotate selector dial. Set dial between 1 to 2% of battery capacity (mp Hours). Figure 1: Current Limit/attery Charge Level - Dial 7 hone:

8 6 C) Time uffering/attery Run Time This function determines how long the reserve battery will power the system in the event of failure. You may choose a specifi ed time or run until the LVD activates. Settings: dial in time interval of desired run time of battery without disconnect. Using small screw driver to set the dial arrow to the desired setting: a. 1-6 minutes or b. Set at zero for battery run until LVD 1.5 VDC (1.75 VC) Figure 11: Time uffering/attery Run Time - Dial D) System Settings Via plug-in jumper programing terminals located on top of the unit. Install jumper per illustration below to: ii. nable attery Test iii. Disable/nable Load riority Function Setting attery Test N Insert Jumper: os os. 4 Insert jumper at position 4 to enable eriodic attery condition test process. (Fault reported by LD diagnosis blink code, see Table 6): attery wiring connection attery efficiency/sulfation (impedance tesst) Shorted Cell Load riority Disable (akes full power available for charging) Insert Jumper: os os. 7 Jumper inserted into position 7 making all power from the unit available for battery charging by disabling the load priority output function. Under low battery charge condition, output voltage to load will be equal to that of the battery voltage, thus useful voltage to the load will not be available until the battery recovers to proper levels. 5) peration 8 ) attery Start without resent ush utton: If system shuts down due to loss of and battery power, pushing button will allow battery to come on line to supply the load. ress and hold for seconds to re-connect battery to output. Note, if LVD has activated and battery voltage has not recovered above disconnect point, the unit will not cycle on. ) Status Indicator LD s 1. ower source: ains or back up i. K ( Fail LD ff) or ii. perating on battery backup power ( Fail LD n) red 2. Low battery, or battery replacement LD illuminates when: Low attery (capacity less than %) ad connection to battery attery requires replacement diagnosis LD. Figure 12: attery Start LD Charger output status system diagnosis and Fault mode diagnosis: by blink code (Table 6 on next page) Figure SLCTIN1: Status Indicator LDs 1 2 TI UFFRING STRT DIN-US 12-5 INUT: 115-2Vac UTUT: 12Vdc 5 i LW R LW R DIGNSIS IN X CHRGING LVL T R INUT L JUR FRhone: N

9 Table 6: Status Indicator LDs onitoring Control State LD Diagnosis (No.8) LD attery Fault No.7) Float 1 link/sec FF Charging Type bsorption 2 link/sec FF ulk 5 link/sec FF Reverse polarity or 1 link/pause* N high battery Voltage attery Not connected, 2 link/pause N no output power attery shorted cell link/pause N ver Load or short 4 link/pause N circuit on the load ad battery; Internal 5 link/pause N impedance ad or ad battery wire connection attery Life test not 6 link/pause N possible Temp. Sensor outside 7 link/pause N System uto Diagnosis its range oost condition; battery 8 link/pause N discharge after 4 min. of overload. Internal fault 9 link/pause N Low battery detected 1 link/pause N when system activated by battery start button with no ac input Life test not possible; 12 link/pause arallel mode on Slave Device ad battery wire 1 link/pause connection; arallel mode on Slave Device * ause: 1 Second C) LVD) The unit contains a low voltage load disconnect that activates at 1.5 volts (1.75 vpc) which is factory set and cannot be user modified. (See also Section 4-C regarding operation with battery time out circuit) 6) rotection n the Input: the device is equipped with an internal fuse. If the internal fuse is blown, it is most probable that there is a fault in the unit. If this occurs, the unit must be returned to the factory. n the DC uput attery and Load: The device is electrically protected. Reverse polarity: the module is automatically protected against reverse of battery polarity and connection of reverse polarity. ver current and output short circuit: the unit limits the output current. Low voltage disconnect protects battery from deep discharge. 9 hone:

10 Thermal protection perating temperature range -12 to 7 C. Unit will produce full rated power on continuous basis to 5 C, however; system load must be reduced by 2.5% per 1 for continuous operation above 5 C. If the temperature reaches 7 C, the unit will reduce its maximum output to approximately 5% of its rating. If the temperature exceeds 7 C, the unit will shut off and restart once temperature drops. 7) Specifications Input: Voltage: 9-15/ hz mperage: 12 V / 2 V utput: 12 volts, 5 amps total available to power loads and charge battery, with load priority distribution. eak: 7 amps 4 seconds (with battery power boost) utput ground isolated from case, may be used in positive ground applications. LVD function is lost Front anel LD Indicators: ower Source: operating on back up red Fail LD attery and System Diagnostics (via blink code) Settings/Selectors: attery Type: G (Sealed Lead), Gel-Cell and pen Lead (Flooded Cell) attery Charge Current Limit: 2-1% of charge amperage rating ack-up Run Time on atteries: rogrammed time limit: 1-6 min. r Until LVD 1.5V ower Restore utton: connects battery without present larm Contacts (form C): ctive: Fail (on battery back-up) attery abnormal condition (summary contact): Discharged, damaged, disconnected, sulfated/short circuit, reverse polarity, bad thermal sensor perating Temperature: -12 to 7 C. Continuous to 5, de-rate 2.5% per C >5 C Cooling: Free air convection fficiency: 91% Humidity: to 95%, to 25 C rotection: Low Voltage disconnect at 1.75 volts per cell (1.5 VDC) Internal fuse Current limiting Short circuit Reverse polarity Thermal overload shut down and recovery I 2 Designed to UL 195 Terminal locks: Screw type ounting: DIN Rail racket 5 mm 1 hone:

11 8) Troubleshooting Symptom ossible Cause Corrective ction Section. attery requires excessive re-charge time. Load turns off after a couple of seconds when running on battery C. No absoprtion voltage D. Unit does not turn on 1.Load at or near max. recommended load providing minimal current available for charging 2.Charging level current set to low 1.Time buffer set to incorrect position 2.atteries not charged, due to high load demand 1.Reduce load or split load between two separate DIN US units 2.djust attery Charging Level control knob to higher level 1.Verify correct setting with manual 2.Reduce load or split load between two separate DIN US units 1. bsorption jumper not installed 1. Install provided jumper in position 6 1. input is 115 V, no jumper wire installed 1. Install 115V jumper wire across j1 and j2. Trips input breaker 1. shorted to case 1. Verify correct input wiring 2. Defective unit 2. Contact technical service F. No output G. No voltage on battery output terminals 1. DC output wired backwards or shorted 1. Remove input and check DC wiring 2. No input 2. Verify correct input and jumper wire installed if powering from 115 V. xcessive temperature or blocked ventilation. Improve ventilation, unblock vent holes 4. Defective unit 4. Contact technical service 1. No battery installed (voltage 1. Install batteries required for battery output to turn on) 2. issing or blown battery wiring fuse 2. Replace missing or blown battery wiring fuse H. Diagnosis LDs always blinking 1. Normal operation 1. Refer to Chart 2: Diagnosis Table 9) Warranty Newmar warrants that the DIN-US 12-5 DIN Rail US to be free from defects in material and workmanship for two years from date of purchase. If a problem with your DIN-US 12-5, or if you have any questions about the installation and proper operation of the unit, please contact NWR s Technical Services Department: hone: From the hours of 7: a.m. to 5: p.m. weekdays,.s.t.; -mail: techservice@newmarpower.com 11 hone: