Uninterruptible Current Supply USV 011 +24 V / 1.2 Ah The USV 011 Uninterruptible current supply is used t buffer the +24 V supply f an Industry PC (C-IPC, SIPC). The +24 V supply is nrmally cnnected t the +24 V utput and is use t lad the internal battery. In the event f a pwer lss, the internal battery absrbs the current frm the +24 V supply. An adjustable USV time prvides a flexible buffer time that serves t execute a cntrlled shutdwn f the Industry PC. Technical Data Perfrmance data Internal energy strage (Battery) USV-time Lad circuit Interfacing Status LEDs 2 x +12 V / 1,2 Ah maintenance-free lead batteries Cnfigurable thrugh the sftware and DIP switches frm 4 t 692 Secnds Cnstant current / cnstant vltage current: 270 ma t 350 ma vltage: Temperature cntrlled 1 x RS232 (2 x cnnectins) 2 x +24 V (input & utput) 3 x battery status 3 x USV Status 16.04.2010 Page 1
Electrical requirements Supply vltage (+24 V-input) Current cnsumptin (+24 V-Input) Supply vltage (+24 V-utput) Current lad (+24 V-utput) Typically +24 V DC +18 V t0 +30 V DC Depends n the lad cnnected t the +24 V-utput Internal current cnsumptin: Maximum 500 ma Typically +24 V DC +18 V t +30 V DC Maximum 3,0 A Miscellaneus Article number 01-470-011 (Sigmatek fil) 01-470-011-O (withut fil) Hardware versin 1.x Weight Typically 2,2 kg (with 2 batteries) Envirnmental cnditins Strage temperature -20 +60 C Operating temperature 0 +40 C 1) Humidity EMV stability 0 95 %, uncndensed Accrding t EN 61000-6-2:2001 (Industry area) Shck resistance EN 60068-2-27 150 m/s² Prtectin EN 60529 IP 20 1) At lwer temperatures, the available battery capacity sinks and the charge time is significantly lnger. At higher temperatures, the self-discharge rate rises and the battery can be damaged thrugh lss f fluids. Self-discharge at 50 C: 0,5 % (capacity per day) Self-discharge at 60 C: 1,0 % (capacity per day) The capacity f the built-in lead batteries is nt defined in factry cnditin. The USV must charge fr 5 hurs befre being cnnected t a lad fr the first time t ensure the functin f the lead batteries! Page 2 b 16.04.2010
Mechanical Dimensins 16.04.2010 Page 3
Cnnectr Layut Page 4 16.04.2010
Cnnectrs +24 V supply input (4-pin Phenix RM3,5) 1 Pin Functin 1 +24 V 2 +24 V 3 GND 4 GND +24 V supply utput (4-pin Phenix RM3,5) 1 Pin Functin 1 +24 V 2 +24 V 3 GND 4 GND X1: RS232 cnnectin t C-IPC (6-pin Phenix RM3,5) 1 Pin Functin 1 RxD 2 TxD 3 RTS (USV Off) 4 CTS (+24 V OK) 5 DCD (battery weak) 6 GND Status lines Signal Lgic status Signal status Meaning RTS HI <+3 V Deactivate USV *) CTS HI <+3 V USV is active DCD HI <+3 V Battery is weak T establish a cnnectin t the C-IPC, a 1:1 cnnectin must be used. The maximum length shuld nt exceed 5 m. A shielded cable is recmmended but nt required the sftware interface ver RxD / TxD is nt used. *) This is the default value and cannt be changed thrugh the sftware! 16.04.2010 Page 5 a
X2: RS232 cnnectin t the S-IPC (9-pin DSUB scket) 1 6 9 5 Pin Functin 1 DCD (battery weak) 2 RxD 3 TxD 4 Nt used 5 GND 6 Nt used 7 RTS (USV Off) 8 CTS (+24 V OK) 9 Nt used Status lines Signal Lgic status Signal status Meaning RTS HI <+3 V Deactivate USV *) CTS HI <+3 V USV is active DCD HI <+3 V Battery is weak T establish a cnnectin t the S-IPC a 1:1 cnnectin must be used (RS232 extensin plug scket). The maximum length cannt exceed 5 m. A shielded cable is recmmended but nt required the sftware interface ver RxD / TxD is nt used. *) This is the default value and cannt be changed thrugh the sftware! Applicable cnnectrs X1: 6-pin Phenix FK-MCP 1,5/6-ST-3,5 X2: 9- pin DSUB plug Supply (2 x): 4-pin Phenix FK-MCP 1,5/4-ST-3,5 The cmplete C-DIAS CKL 016 cnnectr set with spring terminals is available at Sigmatek under the article number 12-600-016. Page 6 a 16.04.2010
Status Display USV status Battery status USV Status Red Yellw Green The USV is ready (Battery r charging circuit is defect, Analg measurement defect, ver temperature) The USV is active, the battery is supplying current The USV is in Standby, the +24 V Input supply is available Battery Status Red Yellw Green Battery is empty (The lw charge threshld was exceeded) Battery is charging (lad circuit is active) Battery is fully laded (The battery accepts n mre current it culd als be that n battery is cnnected. 16.04.2010 Page 7
USV Time S1 S2 S3 USV time Minimum Maximum OFF OFF OFF 4 s 5 s OFF OFF ON 9 s 11 s OFF ON OFF 18 s 22 s OFF ON ON 35 s 43 s ON OFF OFF 71 s 87 s ON OFF ON 142 s 173 s ON ON OFF 283 s 346 s ON ON ON 566 s 692 s DIPswitches S1 S3 define the maximum USV time (independent f the USV time setting in the sftware). Therefre a lnger USV time cannt be set using the sftware! This functin can be seen as a safety circuit. DIPswitch S4 has the fllwing functin: OFF... ON... The time set using the DIP switches serve as an emergency shut dwn. The USV must be activated thrugh the sftware befre the battery can absrb the lad current. Cmmunicatin ver the RS232 interface is imperative fr this functin r the USV. As lng as n new USV time is sent, a default value f 3 minutes is set. Sftware mde The USV time set with the DIPswitches is active independent f the sftware cnfiguratin. N RS232 cmmunicatin is required (but still pssible)! Hardware mde Page 8 16.04.2010
USV Switch Pints 1. Switching frm the +24 V input t the battery: +18.5 V With an input vltage f 18,5 V (±0,5 V), the +24 V OK status changes (CTS line frm the RS232). If the switch threshld is exceeded, the +24 V input pwers the +24 V utput and the battery is charged. When the vltage falls belw the threshld, the battery assumes the lad current n the +24 V utput. 2. Battery warning: +19.4 V The lw charge threshld is 19.4 V (±0.5 V). When the battery vltage falls belw this value, the Battery OK signal changes (DCD line frm the RS232). The USV 011 then signals the PC that the battery capacity is depleted and USV 011 the functin is n lnger available. 3. Battery prtectin: +17.6 V As sn as the battery vltage falls belw 17.6 V (±0.5 V), the USV 011 is deactivated (independent f the RTS signal frm the RS232). This safety functin shuld prtect the battery frm a lw charge, thus extending the battery life. 16.04.2010 Page 9
4. Charging circuit As lng as the battery has nt reached its nminal vltage, it will be charged with a cnstant current surce, which supplies a current f 310 ma (±40 ma). As sn as the battery has reached its nminal vltage, the charging circuit changes t the temperature cntrlled vltage surce mde. Because at lw temperatures the chemical prcess is slwer, the charging vltage must be raised. Temperature Charging vltage 0 C +28.9 V 10 C +28.7 V 20 C +28.4 V 30 C +28.0 V 40 C +27.6 V 50 C +27.2 V 1) 60 C +26.8 V 1) 1) Charging prcess can already lead t a lss f fluid! Page 10 16.04.2010
RS232 Cmmunicatins Prtcl 1. Status bits The USV 011 sends a status t the PC as required. This is defined as fllws: HI-Byte LO-Byte 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 USV Errr USV Status Battery errr Battery status LO-Byte: Battery status and errr D0: 1 = Battery is fully charged D1: 1 = Battery is charged with cntinuus current D2: 1 = Battery is charged with a temperature cntrlled cnstant vltage surce D3: 1 = Warning: The battery capacity is lw D4: 1 = Errr: batteries are charged asymmetrically D5: 1 = Errr: battery current is t high (hardware errr) D6: 1 = Errr: the discharge current is t high D7: 1 = Errr: The battery temperature is t high HI-Byte: USV status and errr D0: 1 = USV is n standby, battery OK D1: 1 = USV is active, the USV time is running D2: 1 = USV is deactivated (RTS line frm the RS232 r sftware instructin) D3: 1 = Warning: the battery is almst empty (lw charge threshld has been reached) D4: 1 = Errr: charging circuit, analg value measurement defect (Hardware errr) D5: 1 = Errr: the batteries are charged asymmetrically r empty D6: 1 = Errr: The discharge current is t high D7: 1 = Errr: The ambient temperature is t high Cautin: an verlad f the battery caused by t high a discharge current r envirnmental temperature can damage the battery! 2. Cmmunicatin parameters Baud rate 9600 Baud Data bits 8 Stp bits 1 Parity Nne 16.04.2010 Page 11
3. USV 011 cmmunicatin prtcl Basically, 3 bytes are sent t the USV. The USV returns a 4-byte answer. Each data transfer starts with STX ($02) and ends with ETX ($03) 3.1 Set USV time: (The maximum USV time set with the DIP switch are measured in secnds) Start 1. Byte 2. Byte 3. Byte End STX $00 USV time (L-Byte) USV time (HI-Byte) ETX As lng as n USV time is sent, the default value f 189 secnds (3 minutes) is set. Answer: Start 1. Byte 2. Byte 3. Byte 4. Byte End STX Battery status USV status USV time (L- USV time (HI- ETX Byte) Byte) 3.2 Deactivate USV: Start 1. Byte 2. Byte 3. Byte End STX $01 $00 $00 ETX Answer: Start 1. Byte 2. Byte 3. Byte 4. Byte End STX Battery status USV status $00 $00 ETX Page 12 16.04.2010
3.3 Read analg values: Start 1. Byte 2. Byte 3. Byte End STX $02 $00 Inf ETX Answer: Inf: $00: USV time $01: Vltage f battery 1 $02: Vltage f battery 2 $03: Vltage f bth batteries (batt 1 + batt 2) $04: Vltage f bth batteries with a 1 A electrnic lad $05: Battery current (battery is charging) $06: Current frm the battery (lad current with active USV) $07: Internal resistance f the battery Start 1. Byte 2. Byte 3. Byte 4. Byte End STX Battery status USV-Status Analg value (LO) Analg value ETX (HI) The analg input values are standardized by the USV 011: Analg value Range Digital value Reslutin Precisin Batt 1 0,0 V.. +15.0 V 0.. 150 10 d / V ±0.1 V Batt 2 0,0 V.. +15.0 V 0.. 150 10 d / V ±0.1 V Batt 1 + Batt 2 0,0 V.. +30.0 V 0.. 300 10 d / V ±0.1 V Batt 1 + Batt 2 (with 1 A 0,0 V.. +30.0 V 0.. 300 10 d / V ±0.1 V lad) Lad current 0,00.. +0.80 A 0.. 80 10 d / ma ±10 ma Discharge current 0,00.. + 5.50 A 0.. 550 10 d / ma ±10 ma Internal resistance 0,0 Ω.. 30.0 Ω 0.. 300 10 d / Ω ±0.1 Ω I.e.: A vltage f 123 d crrespnds t 12.3 V A current f 45 d crrespnds t 450 ma (0.45 A) A resistance f 67 d crrespnds t 6.7 Ω 16.04.2010 Page 13
3.4 Read EEPrm Start 1. Byte 2. Byte 3. Byte End STX $03 $00 EE-Inf ETX Answer: EE-Inf: $00: Mdule header + calibratin data $01: Header + charge histry $02: Header + discharge histry Start 1. Byte 2. Byte Data End STX Battery status USV status Data ETX Data: $00: Mdule header + calibratin data Data: 256 Bytes $01: Header + charge histry Data: 8 + 1440 Bytes $02: Header + discharge histry Data: 8 + 240 Bytes 3.5 Set RTS Plarity Start 1. Byte 2. Byte 3. Byte End STX $04 $00 RTS-Plarity ETX Answer: RTS-Plarity: $00: RTS lgic HI = deactivate USV (Default) $FF: RTS lgic LO = deactivate USV Start 1. Byte 2. Byte Data End STX Battery status USV status RTS-Plarity ETX Page 14 a 16.04.2010
3.6 Service mde (read raw values): Start 1. Byte 2. Byte 3. Byte End STX $FF $00 Inf ETX Answer: Inf: $00: Read Digital Inputs frm the cntrllers $01: Raw vltage value batt 1 + batt 2 $02: Raw vltage value batt 2 $03: Raw current value Start 1. Byte 2. Byte 3. Byte 4. Byte End STX Battery status USV status Raw value (LO) Raw value (HI) ETX Digital Inputs: D0: 0 = +24 V Input vltage available D1: 0 = Battery vltage OK (abve the lw charge threshld) D2: 0 = Battery is full D3: 0 = USV deactivated D4: 1 = Deactivate USV (RTS Signal frm RS232) 3.7 Service mde (write digital utput): Start 1. Byte 2. Byte 3. Byte Ended STX $FF $01 Digital utputs ETX Answer: Digital utputs: D0: 1 = Deactivate charging circuits D1: 1 = Activate USV (release battery) D2: 1 = Activate electrnic lad (1 x with shrt 1 A lad) D3: 1 = disable symmetry (= deactivate analg measurement) D4: 1 = disable USV status led (red) Start 1. Byte 2. Byte 3. Byte 4. Byte End STX Batt status USV status $01 Digital utputs ETX 16.04.2010 Page 15
3.8 Service mde (write t EEPrm): Start 1. Byte 2. Byte Data End STX $FF $AD Calibratin data ETX Answer: Calibratin data: Mdule header + Calibratin data Data: 256 Byte Start 1. Byte 2. Byte 3. Byte 4. Byte End STX Batt Status USV Status $AD $00 ETX Each service mde ends the autmatic functin f the USV 011! The service mde cannt be used fr the nrmal functin f the USV 011! It serves nly fr precise errr analysis and testing by Sigmatek. Page 16 a 16.04.2010
4. EEPrm Data 4.1 Mdule header (rganized by Byte) Address Data Descriptin $00 $xx Checksum $01 123 Identificatin $02 221 Mdule grup 221 = USV $03 1 Variant 1 = USV 011 $04 3 Number f channels $05 $1x Hardware versin $10 = HW-V1.0, $11 = HW-V1.1, 4.2 Calibratin data (Address = Byte, Data is rganized by Wrd, Little Endian / Intel Frmat) Address Data Descriptin $40 $xxxx Checksum $42 12345 Identificatin $44 10 Length f the fllwing data blck in WORD $46 $0003 Number f channels (2x vltage, 1x current) $48 I.e. 0000 Vltage ffset fr batt 2 $4A I.e. 0150 Gain multiplicand fr the vltage f batt 2 $4C I.e. 1024 Gain divisr fr the vltage f batt 2 $4E - $52 - Calibratin values fr the vltage f bth batteries (batt 1 + batt 2) $54 - $58 - Calibratin values fr the current measurement Calculatin f the analg input values I.e.: Offset 0000 Gain multiplicand 0250 Gain divisr 0256 Cnversin frmula fr analg inputs Value = ( Rawvalue + Offset) Multiplicand Divisr This calculatin f the analg value is dne by the USV 011! 16.04.2010 Page 17
4.3 Header (Address = Byte, Data is rganized by Wrd, Little Endian / Intel Frmat) Address Data Descriptin $00 $xxxx Pinter t the current start address (first valid entry) $02 $xxxx Pinter t the current end address (last valid entry) $04 $xxxx Pinter t the last start address (Backup) $06 $xxxx Pinter t the last end address (Backup) The data is stred in a ring buffer; the last value is verwritten with the updated value. The valid data is lcated between start address and the end address. A backup f the pinter makes it pssible t recnstruct the last charge/discharge prcess after a new charge/discharge prcess has been started. 4.4 Charge histry (Address = Byte, Data is rganized by Wrd, Little Endian / Intel Frmat) Address Data Descriptin $00 $xxxx Vltage f battery 1 $02 $xxxx Vltage f battery 2 $04 $xxxx Charging current $06 $xxxx Internal resistance The data is stred successively (address $08 cntains the vltage frm battery 1). Updated values are written t the EEPrm each minute. This results in a histry f 720 wrds/4 = 180 minutes 4.5 Discharge histry (Address = Byte, Data is rganized by Wrd, Little Endian / Intel Frmat) Address Data Descriptin $00 $xxxx Vltage batt 1 + batt 2 $02 $xxxx Discharge current The data is stred successively (address $04 cntains the vltage frm battery 1 + battery 2). Updated values are written t the EEPrm each secnd. This results in a histry f 120 wrds/2 = 60 secnds Page 18 16.04.2010
Batteries The batteries can be changed by remving the battery cvers; the batteries can than be remved individually. Thereafter, the new batteries are inserted and the battery cable recnnected. An empty battery requires apprximately 10 hurs until it s fully recharged. The batteries shuld nt be changed when vltage is present! FIRM TYPE DATA Lead battery EXIDE / SONNEN- SCHEIN A512 / 1.2 S 12 V / 1.2 Ah Calculatin fr the battery lifespan: Battery capacity: 1,2 Ah Cycles: 300 Life span cycles: 300 x 1,2 Ah = 360 Ah Theretical USV charge/discharge cycles: Lifespancycles 3600 USV Zeit Ladcurrent Lifespan cycles = 360 Ah USV time = USV time in Secnds Current lad = lad n the +24 V utput in ampere Cautin: This calculatin des nt include temperature-dependant deteriratin. I.e.: Lifespan cycles = 360 Ah USV time = 10 Secnds Current lad = 3 ampere Theretical USV charge/discharge cycles: Lifespancycles 3600 USVtime Currentlad 360Ah 3600 = = 43200 10s 3A As a rule, the batteries must be changed yearly under nrmal cnditins. 16.04.2010 Page 19
Battery Rating 1. Battery vltage The fllwing vltages can be measured ver the hardware: Vltage frm batt 1 + batt 2 (ttal vltage) Vltage frm batt 2 With these tw measurements, the vltage frm each battery can be determined. Unfrtunately, establishing a direct crrelatin between the battery vltage and the capacity is nt pssible. The fllwing errr cnditins can be detected with the vltage measurement: Asymmetric Battery charge: If the battery vltage shws a difference f mre than 3.0 V, it is a gd indicatin that the USV 011 functin is strngly impaired since the batteries shw a difference in capacity. A symmetrizatin integrated in the USV 011 ensures that the battery vltages (capacity) are equalized. This prcess, hwever, can require several hurs. Empty batteries: A vltage smaller than +5 V indicates a battery with a lw charge. If the battery is stred ver a lnger perid with such a lw vltage, a defect is highly prbable. Sulfate crystals frm utward frm bth lead plates that, in the wrst case, can frm a bridge in the middle causing a shrt circuit. In additin, the internal resistance increases massively because the sulfate crystals reduce the electrn-transprting surface f the lead plates. 2. Battery current Bth the charging and discharging current can be measured. An errr has ccurred when: If the charging current is ver 500 ma, the charging circuit r analg measurement is defect. T avid further damage, the charging circuit shuld be deactivated and the USV 011 shuld be exchanged. The discharge current exceeds 5.0 A. Such high discharge current places extreme stress n the battery and the ttal capacity cannt be utilized. Page 20 16.04.2010
3. Internal resistance The USV 011 has an integrated measurement fr internal resistance. The battery is laded fr a shrt time with 1 A and the charging circuit is deactivated simultaneusly. The internal resistance is dynamic and is calculated using the frmula: du du Ri = = = du di A 1. Because the current lad is 1 A, the vltage difference between laded and lad-free batteries is equals the internal resistance. The internal resistance determines the fllwing: High impedance battery: if the internal resistance is cntinuusly ver 2,0 Ω, the battery is either empty r defect. A battery that has exhausted its lifespan cycles but reaches its nminal vltage relatively fast indicates high internal impedance. The same effect can ccur in a battery with a lw charge (<5.0 V). Empty battery: an Initially high internal resistance that decreases with the charging time is nrmal and means that the battery capacity is slwly increasing. Cable break: an internal resistance larger than 10 Ω means that there is n battery cnnected r the cnnectr cable is defect. 4. Histry The battery histry prvides a gd basis fr estimating whether the USV 011 can bridge a new USV time. Frm the charge histry, hw the battery vltage, current and internal resistance behaved during the charging prcess. Observing the charge histry: A battery that des nt absrb current after discharging and reaches its nminal vltage quickly is and indicatin f lw capacity and high internal resistance. A battery that des nt reach its nminal vltage has ne r mre shrt-circuited cells internally. Observing the discharge histry: The battery vltage at the end f the USV time can be used as a criterin fr estimating the residual capacity. A linear crrelatin, hwever, is nt given since the characteristic curve changes with temperature and age. The curve f the battery vltage during the USV time is an additinal start pint. A steep vltage drp is an indicatin f lw capacity r a very large lad. 16.04.2010 Page 21
Munting Guide 1. Munting psitin The lead batteries used are basically acid dense, hwever each cell has a pressure vent t release steam in an emergency. This can happen when the battery is perated in high ambient temperatures. The vent is lcated n tp; therefre the munting psitin shwn abve is the nly ptin pssible. Page 22 16.04.2010
2. Envirnmental temperature High envirnmental temperatures lead t greater self-discharge: Self discharge at 50 C: 0,5 % (capacity per day) Self discharge at 60 C: 1,0 % (capacity per day) It is strngly recmmended that the battery be kept away frm surces f heat. The life span f the can be reduced dramatically thrugh high ambient temperatures. With the use f cntrl cabinet fans, cautin shuld be taken t ensure that the USV 011 is place in the path f the cl air. The functin f the USV 011 is rated fr a maximum temperature f +40 C. The battery is als affected even when it s just n standby. 16.04.2010 Page 23
Wiring Guide Cnnectin S-IPC +24 V frm pwer supply The +24 V frm the pwer supply/transfrmer is cnnected t the +24 V input. The +24 V utput f the USV 011 is cnnected t the S-IPC (C-IPC r any prcessr mdule). The RS232 cmmunicatin is established by the S-IPC ver X2 f the USV 011 t COM1 r COM2 f the S-IPC (A USB RS232 cnverter can als be used n the S-IPC in case COM1 and COM2 are already in use). Cnnectin t C-IPC Supply vltages: see abve RS232 cmmunicatin is established with the C-IPC ver X1 f the USV 011 t X11 f the C-IPC Page 24 16.04.2010
Cnfiguratin f the Windws USV Driver (Standard) Advantages: N functins integrated in the applicatin are necessary The USV wrks in hardware mde Disadvantages: The USV time set with the DIPswitch must be smewhat lnger as the USV time set in windws N battery mnitr can be integrated in the applicatin since the USV driver ccupies the entire serial prt. Defective r empty batteries are nt detected by the applicatin. When nt cnnected, the USV 011 shuts dwn directly after start-up. 16.04.2010 Page 25
1. Open Energy Management Open Start settings System Display Then select the Screen saver tab Open Energy management Select the USV tab In Windws 2000, it is pssible that under the APM tab, Activate supprt fr advanced pwer management must be selected ( ). Page 26 16.04.2010
2. Select USV Driver Press Select... Select manufacturer: Standard Select mdel: User defined Cnnectin: select serial Interface fr the USV 011 Next press cntinue > 16.04.2010 Page 27
3. Set Signal Plarity Select plarity negative as shwn abve. Page 28 16.04.2010
Cnfigure USV Press Cnfigure... 1) 2) 3) 4) Windws detects the CTS signal frm the RS232 as sn as the supply vltage falls ut and the USV 011 changes t battery peratin. Frm this pint n, the USV time is running. 1) Ntificatins can be used that require the user t save all imprtant data. 2) Under Remaining minutes n battery befre critical alarm, the bridging time (minimum 2 minutes) can be set. Please make sure that the USV time set with the DIPswitch is lnger! 3) After the time has elapsed, a critical alarm is triggered, which autmatically clses all prgrams and shuts the PC dwn. If the battery discharges befre the specified time has elapsed, Windws detects the DCD signal frm the RS232. In this case a critical alarm is generated immediately and the PC is shut dwn. 4) After a successful shutdwn, the USV is deactivated ver the RTS line f the RS232 (with a 10 secnd delay). 16.04.2010 Page 29
Revisin Histry USV 011 Date Revisin Reasn 14.03.2006 1.0 Charge / discharge histries are nt implemented 31.03.2006 1.1 Charge / discharge histries are implemented 24.04.2006 1.1 RTS Plarity cnversin expanded Page 30 16.04.2010