12/24V 20A High Performance DC-UPS - Asi
Contents
1. Figure 2 DCU20 simplified blockdiagram DCU20 is a high performance digitally controlled DC UPS that can be used in any DC system with a rated voltage between 12V and 28V and up to 20A of input current It includes a battery charger capable of charging Lead Acid Ni MH and Li ION batteries with a rated voltage between 12V and 28V and able to deliver a charge current up to 5A The input voltage is continuously monitored by the microprocessor In case of a power outage the battery is connected to the load instantaneously through an active switch reducing the power loss to aminimum The product offers additional features to improve the performance and the reliability of the system which are described below 3 1 Remote monitoring and controlling 3 1 1 USB The USB interface allows the communication with the proprietary POWERMASTER software which allows the full control and monitoring of the DCU20 unit with the ease of the PC 3 1 2 Digitalinput An opto isolated input allows the inhibition of the backup function The polarity of the input can be defined using the Inhibit polarity setting see 5 2 14 3 1 3 Dry contact outputs 2 relays are present on the DCU20 User can chose which event activates the relay and the polarity The list of events is the following DCU20 User Manual rev 16 Page 7 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions Name Description CCC Default setting Backup Active w2. The main features are e Integrated battery charger for multi chemistry batteries with charging current up to 5A e Automatic sensing of input voltage load current and battery current e Protections against battery reverse polarity connection and over current when operating from the battery e Battery health monitoring system measuring battery internal resistance battery temperature and providing a Coulomb counter e User settable maximum backup time e Remote input to inhibitthe UPS function e Connection of a battery thermal sensor optional e Integrated dataloggerwith time stamp allevents errors are loggedinthe internal memory and downloadable through the USB interface e Automatic PC shutdown restart function see 3 3 Embedded user interface e 4 buttons and 1 color graphic CSTN LCD Displays the set up status measures and alarms e Online device configuration e USB portfor remote monitoring and configuration e Dry contacts for status monitoring POWERMASTER PC application e Connection through USB interface e Remote monitoring and configuration e Firmwareupgrade e Same functionalities ofthe embeddeduser interface withthe ease ofthe PC benefits DCU20 User Manual rev 16 Page 6 29 W W W ASI EZ COM innentive Interconnect and Interface Solutions 3 Functional description A simplified block diagram of the DCU20 is shown in Figure 2 t O i gt Kun aa Microprocessor
3. 23 A a ne AE A A 23 6 Events and Alal MS 22 ee ee dort Savages wooo ee berbere db Ekke 24 7 Technical Speciications sce ns ck eos cesosinse EE EEEE E EE es eh eau auecies wpe ERNA DMR eee ae oena SE 28 DCU20 User Manual rev 16 Page 4 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 1 System description The DCU20 is a microprocessor controlled DC UPS rated 20A rating of the power supply connectable to the input usable in systems with a nominal voltage between 12V and 28V The DCU20 monitors the voltage coming from a DC power supply and in case of power failure a backup battery is connected to the load In normal condition the battery is kept charged by an integrated battery charger supporting various battery chemistries such Lead Acid NiMH NiCd and Lithium 1 Alarm LED indicator It is ON when the unitis in backup It blinks at 1Hz rate in case of error 2 USB Port Used to connect a PC running the POWERMASTER application for remote 2 10 monitoring and controlling Firmware update is also possible through USB connection m 3 Temperature sensor connection Used to E Fr connect a temperature sensor P N WNTC 2MT to measure the battery temperature for protection and temperature compensated 13 charge method Fa 4 Relays dry contacts 2 relays are presentfor p enor sack remote monitoring See 3 1 for more details Ei 5 Inhibit input A signal between 5VDC and 6 ae 30VDC applied to this i
4. between start of PC shutdown and output power OFF see 3 3 for details PC shut time Default Os gt m 5s5 Range Os 10min PC rest off T Resolution 1s Pc off det I 5 2 24 PC restart minimum OFF time PC shut delay BC shut time Minimum OFF time for PC restart see 3 3 for details When set to O the PCrestart EEE function isdisabled gt m s Default Os PC off det I Range Os 60s PC off det T Resolution 1s 5 2 25 PC OFF detection current threshold PC shut time PC pest off T Current threshold for PC OFF detection see 3 3 for details When set to O the PC EE restart function is disabled Default OA Range OA 20A Resolution 0 1A 5 2 26 PC OFF detection timer Timer user for PC OFF detection see 3 3 for details PC off det T Default 1s gt m 12s5 Range 1s 60s Relay 1 ready Resolution 1s jee ATMU 5 2 27 Relay 1 Ready Date dd mm yyyy ime hh mm ss Used to configure the behavior of the Relay 1 contact Click OK and then follow the SiRF instruction on the screen to define the polarity and event associated with the relay gt Configure See 3 1 3 for more details Relay 2 backup Input nom volt DCU20 User Manual rev 16 Page 21 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 5 2 28 Relay 2 Backup ime hhimm ss Relay 1 ready Used to configure the behavior of the Relay 2 contact Click OK and then follow the ESEREREEm instruction on th
5. ed to ee en ere en me 14 4 1 Connecting the input to the power supply iii 14 42 COHEN NOIR a ee os a ame a eo ou 14 4o Connecting THE Date nm te rene lan et er rien 14 4 4 Connecting the temperature Sensor iii 14 4 5 Connecting the INHIBIT input csuicccictavsssissvdcscsusavsosssivecassetangosisssivrcseanoseusarsnsissedyassvosavivanebeasivescsedavaeaisusectosesnnseas 15 AO DECO accesses access rset N EEE EE E AE ate oe Seen EEEE EET anata 15 AT Battery sense OCCU OA ao de e ERE onen Ed 15 SSSR DEER ene ee ee en een ery ae Lee Rees ee ai Rs en een Nhe oo En DN KER dre AE 16 a 17 Ode en de a REE RRE 17 52 1 Mp utnomnal VOA eee eee ra eee ee 18 522 Banery Chemis Uy erea e E EE E EEEE E 18 5 2 3 Battery nominal voltage acess teat cic sa teasescedetanc de sewdaneide sedsateasabsecdtnes keen tern kreert ca iadslacs sa sedanceddnatelateasnbsetdaden dei 18 sed Battery CO E OE ESS ENES EEE EAEEREN EEEE 18 5 2 5 Battery charge voltage ee 18 526 Battery charge CMOS ee aei a a ce ere ee si 18 5 2 7 Battery deep discharge voltage ss 18 5 2 8 Battery nominal internal resistance iii 19 5 2 9 Battery maximal internal resistance variation eee cc cescceesseceeeseeeeesseeceesseccesseeceesseecesseseesseeesaeees 19 52 10 Battery maximum temperature 22223 Nee nde eg 19 5 2 11 Battery minimum temperature sise 19 5 2 12 Battery One ea nee ee ae et ne en ESES 19 5 2 13 Maximum backup AB ee na Qu bn ec e
6. the event logs 9 2 20 Time Used to show and set the current RTC time The RTC is used to time stamp the event logs DCU20 User Manual rev 16 W W W ASI EZ COM Batt lifetime Max backup time Inhibit polarity gt High screen contrast screen backlight Max backup time Inhibit polarity screen contrast gt 24 screen backlight Screen timeout Inhibit polarity Screen contrast Screen backlight timeout state screen contrast Screen backlight Screen timeout gt Smin Buzzer state Date dd mm yyyy Screen backlight Screen timeout Buzzer state gt Enabled Date dd mm yyyy ime hh mm ss Screen timeout Buzzer state Date dd mm wayyy gt 84 86 2614 ime hhimm ss Relay 1 ready Buzzer state Date dd mm 1 Time hh imm ss gt 13 42 83 Relay 1 ready Relay 2 backup Page 20 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 5 2 21 PC shutdown enable Date dd mm yyyy ime hh mm ss Enables the PC shutdown function as explained in 3 3 PC shut enable Default Disabled gt Enabled Choices Enabled Disabled Fe lie Selay PC shut time 5 2 22 PC shutdown delay ime hh imm ss BC shut enable Delay between start of backup and PC shutdown command sent by EST POWERMASTER see 3 3 fordetails gt m 5s Default Os PC shut time Range Os 60min pC rest off T Resolution 1s 5 2 23 PC shutdowntime Pc shut enable PC shut delay Delay
7. when the inhibit signal toggles from true to false Names Shortname Value ALARM INPUT UNDERVOLT START IUVS Threshold voltage triggering the alarm Description The measured input voltage is lower than the alarm threshold The threshold is calculated taking the lowest value between the input nominal voltage 5 2 1 and the battery nominal voltage 5 2 3 10 Name 0 Shortname Value ALARM INPUT UNDERVOLT END IUVE The minimum input voltage reached during the alarm Description The measured input voltage returns above the alarm threshold Name Shortname Value ALARM INPUT OVERVOLT START IOVS Threshold voltage triggering the alarm Description The measured input voltage exceeds the alarm threshold The threshold is the input nominal voltage 5 2 1 30 Name Shortname Value ALARM INPUT OVERVOLT END IOVE The maximum input voltage reached during the alarm Description The measured input voltage returns below the alarm threshold Name Shortname Value ALARM INPUT OVERLOAD START IOLS Threshold current triggering the alarm Description The measured input current exceeds the alarm threshold The alarm threshold is set to 22A Short name _ Value O Z O O O ALARM_INPUT_OVERLOAD_END IOLE The maximum input current reached during the alarm Description The measured input current returns below the alarm threshold DCU20 User Manual rev 16 Page 25 29 W W W ASI EZ COM innovative In
8. Ar WW W ASI EZ COM ren eront ond Interface Solutions DCU20 12 24V 20A High Performance DC UPS User Manual DCU20 User Manual rev 16 Page 1 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions oo p r ye one o n 7 es ay er kant Lu cts aa re s l T Peace CRE see ae 2 EC mi gt rue mage me te em DCU20 12 24VDC UPS AG du pi ann T SENSE DY 4 READY BACKUP INHIBIT INHIBIT _ BATTERY SENSE _ BATTERY SENSE _ Page 2 29 DCU20 User Manual rev 16 W W W ASI EZ COM innentive Interconnect and Interface Solutions TABLE OF CONTENTS DV SET CSS Ci NON 55 a sara ce D ae a ee D an a a in 5 2 Features and benefits notes pence at aies teiadeteepa te lente ion lien laine cannot nere et o een totercaquine 6 J Fun uona CS CID EI M A D ne ii Moon 7 3 1 Remote monitoring and CON ONMINO serons rencontres ea eee teen 7 SRI SR CRO es Oo Cee ee en ee eee cme ee ES te vers Coe rere eee ere ere eer ee a eee eran ee 7 Ska DONDU isc sinse scan wits ss pn oes E E ENE EET BLEER 7 3M3 Dry contact OU UNS sa ee ee E me ct 7 OR a AS 8 3 3 PC shutdown and automatic F SANL metres ere era esse een 8 234 Battery heath HMO FMM ON Sn de ne eee tans lue 10 3 5 Battery resistance measurement naar on ne 11 30 Battery CARRE en de D Go deu ns 11 BT Coulomb CORRE a ni 12 OMC DIS AR ee D es eal E TEE TR 13 VAS TU OU este ae are ra
9. NHIBIT input is not connected the unit will switch the load to the battery as soon as the input voltage is no more present Applying a signal to this input inhibits the backup function and the load can be switched OFF as soon at the input fails with no battery backup The polarity of this input can be changed as explained in 5 2 14 4 6 Dry contacts 2 relays dry contacts are provided on the DCU20 Connect the 2 relays dry contact using 60 75 Class copper 0 15 0 5mm wires stripped 7 8mm The connector is provided with spring terminals Note the 2 relays contacts have one pole in common 4 7 Battery sense connection ze J 40 3 8v fatt T SENSE o pv sil POSE EN BATTERY RENEE OH BATTERY SENSE L D i ia EN READY f BACKUP imi E g iai GA IMHIEIT wi EN NHT T CN BATTERY RENEE BATTERY SENSE ALF U D Le D IN IN OUT OUT BATTERY Rcables Rcable I BATTERY k mm Battery Battery Figure 9 Battery connection withoutsense Figure 10 Battery connection withsense The battery sense connection is optional and it is recommended to use it to have an accurate measurement of the battery internal resistance see 3 5 A Caution please respect the polarity of the battery sense connection DCU20 User Manual rev 16 Page 15 29 innovative Interconnect and Interface Solutions 5 User interface Power ONscreen This scr
10. Used to set the expected battery lifetime Once the battery operating time exceeds ESS the set value an alarm is generated gt 186kh Default 100kh Max backup time Range 1kh 200kh Inhibit polarity Resolution 1kh 5 2 13 Maximum backup time max temp Batt Lifetime Used to set the maximum time the system stays in backup before switching OFF f CEE disabled the system stays in backup until the battery reaches the deep discharge gt 2h m 8s voltage Inhibit polarity Default 2h Screen contrast Range 10s 2h No timeout Resolution 1s DCU20 User Manual rev 16 Page 19 29 innovative Interconnect and Interface Solutions 5 2 14 Inhibit polarity Used to select the polarity of the INHIBIT input The inhibit input prevents the system to enter the backup mode Default High Choices Low High 5 2 15 Screen contrast Used to set the LCD screen contrast Default 24 Range 0 40 Resolution 1 5 2 16 Screen backlight Used to set the LCD screen backlight Default 2 Range 1 10 Resolution 1 5 2 17 Screentimeout To save the LCD backlight the system dims the LCD after the defined timeout value Default 5min Range 1min 30min Disabled Resolution 1min 5 2 18 Buzzer state Used to enable or disable the internal acoustic alarm buzzer Default Enabled Choices Enabled Disabled 5 2 19 Date Used to show and set the current RTC Real Time Clock date The RTC is used to time stamp
11. Z COM innovative Interconnect and Interface Solutions e When the battery is connected for the first time or the system starts from OFF the system assumesthe battery is fully dischargedandstartwithOAh counter e For Lead acid batteries only during battery charge an approximation of charge is done checking the battery voltage e Once the battery is fully charged the system sets the counter to the nominal capacity specified by the user 5 2 4 3 8 Cold start The cold start is a procedure that allows turning ON the UPS without the input power This procedure is used to turn ON the UPS to operate during a power interruption or to determine if the UPS will not turn ON due to a bad input power This practice is also a method to see if the battery connected to the DCU20 isfunctional In cold start the DCU 20 will remain ON for at least 60 seconds independently from the battery voltage being under the deep discharge threshold the inhibit input and the backup timer After the first 60 seconds the device stays ON until the battery is not deep discharged the Max backup timer is not expired or the inhibit input is not active If the input supply returns during cold start the device reverts to normal operation To cold start the DCU20 e Press and HOLD simultaneously the menu button and OK button until you see the welcome message onthe screen Onthe status screen the input voltage status is indicated as COLDSTART e RELEASE thebut
12. and Interface Solutions PC shutdown procedure User settable 5 2 23 Time between start of shutdown procedure and output voltage OFF This time must be set longer than the maximum time the PC takes to complete the shutdown T3 PC restartminimum User settable 5 2 24 T3 is the delay used between the return OFF time of the input voltage and the activation of the output The same time is used by the automatic restart function as power OFF time to restart the PC The value must be big enough for the PC to detect the supply ON gt OFF gt ON cycle to restart T4 PC OFF detection User settable 5 2 26 Minimum time at which the output current timer must be below the loff current threshold to trigger the automatic PC restart PC supply ON gt OFF gt ON cycle loff PC OFF detection User settable 5 2 25 Current threshold used to detect PC OFF current threshold status This value must be lower than the minimum PC current consumption when this is ON Table 2 Shutdown andrestart The parameters are settable through the DCU20 LCD or using the POWERMASTER application as shown on the image below The checkbox Run on startup must be checked on POWERMASTER when PC shutdown function is used select Start in tray to start in minimized into the windows system tray To inhibit the software from calling the shutdown command user can select the Inhibit shutdown checkbox 3 4 Battery health monitor The battery health m
13. and click next to confirm See 5 2 6 for moredetails DCU20 User Manual rev 16 System Wizard Do you Want to continue with he wizard Select battery chemistry ch Exit Select battery capacity Cbat E Exit Select battery charge current Icharge En Exit 2 Insert the input nominal voltage and click next to confirm See 5 2 1 for more details 4 Insert the battery nominal voltage and click next to confirm See 5 2 3 for more details 6 Insert the battery charge voltage and click next to continue See 5 2 5 formore details 8 Insert the battery deep discharge protection voltage and click next to confirm See 5 2 7 for moredetails Select nominal input voltage vinom fRREX Exit Next Select nominal battery voltage Ubat Nom fEREX Exit Next Select battery charge voltage Ucharge Eat Exit Next select battery deep discharge protection Udisch FET Exit Next Page 23 29 innentive Interconnect and Interface Solutions 9 Insert the battery nominal internal resistance and click next to confirm See 5 2 8 for more details 11 Insert the battery expected lifetime and click next to confirm See 5 2 12 for more details 12 The wizard is finished Click the OK KEY to start using the new values in the configuration or the MENU KEY to exit discarding the Select battery nominal internal resistance select battery expected lifetime wiz
14. apacity Higher capacity batteries can also be used at the expense of a longer charging time Use only 60 75 Class copper 1 5 2 5mm7 wires stripped 6 7 5mm The tightening torque must be0 5 0 6Nm A Caution The battery shall be connected to the DCU20 through a 30A ATO fuse or equivalent Even is the unit is electronically protected against short circuit it is mandatory to use a fuse for safety reasons Please respect the wiring polarity Avoid keeping the DCU20 connected to the battery for long time when not used Although the current consumption from the battery when the unit is OFF is very low about 30A it can discharge the battery in thelong time 4 4 Connecting the temperature sensor An optional temperature sensor P N WNTC 2MT can be connected to its input on the front panel The temperature sensor is provided with 2m long cables and must be fixed to the battery body to measure its temperature an adhesive pad can be used When the sensor is connected the battery temperature is automatically displayed on the LCD and a temperature compensated charge is activated when charging Lead Acid batteries DCU20 User Manual rev 16 Page 14 29 W W W ASI EZ COM tnnevative Interconnect ond Interface Solutions 4 5 Connecting the INHIBIT input An opto isolated digital input is provided A digital signal between 5VDC and 30VDC must be applied to this input to enable the INHIBIT function By default when the signal is OV or the I
15. ard finished Click text to save the data or 10 Insert the battery maximum temperature and click next to confirm See 5 2 10 for moredetails 12 Insert the battery installation date and click next to confirm See 5 3 6 for more details W W W ASI EZ COM Select battery aximum emperature M 4 Select battery installation date Date f 12 2012 Exit Next data and keep using the old F it te discard configuration Exit Next 6 Events and Alarms Name Shortname Value EVENT POWER ON Power ON cyclescount Description Triggered at device power ON Name Shortname Value _ _ EVENT_POWER_OFF Power OFF Description Triggered when DCU20 powers OFF Short name Value EVENT BATTERY CHARGING Charging Triggered when the DCU20 starts charging the battery Short name Value EVENT_BATTERY_CHARGED Charged Description Triggered when the DCU20 finishes charging the battery The battery is fully charged Short name _ Value O Z O EVENT_BATTERY_DISCHARGING Discharging Triggered when the DCU20 enters the backup mode DCU20 User Manual rev 16 Page 24 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions Name SSCS Shortname Value EVENT_INHIBIT_START Inhibit start Description S O Description Triggered when the inhibit input toggles from false to true Name Shortname Value EVENT_INHIBIT_END Inhibit end Description Triggered
16. atteries only the following conditions are also checked e Temperature Cutoff TCO The battery temperature if higher than the Battery maximal temperature 5 2 10 minus 3 C for more than one minute For example if the maximal battery temperature is set to 60 C the charge terminates in case the temperature is higher than 57 C e Rate of Temperature Increase AT dt The battery temperature is rising at a rate equal or superior then 1 C min To avoid unattended end of charge don t place the system on an ambient with rapid changes of temperature for example exposed to direct sunlight A Warning In order to avoid potentially hazardous situations including fire hazard safety recommendations must be followed Only authorized staff can install the unit Warning For Lithium cells the balancing and protection circuit must be included in the battery pack A For nickel batteries the use of the external temperature sensor is mandatory The sensor must be placed in contact with the battery 3 7 Coulomb counter DCU20 measures the current flowing from to the battery to keep track of the capacity available on the battery The capacity is measured in Amp re Hours Ah The value shown is based on the following assumptions e The value shown is just informative and does not represent the real state of charge of the battery in some circumstances for example if the battery is damaged DCU20 User Manual rev 16 Page 12 29 W W W ASI E
17. e 0e maine 19 Sea Le A MV PR PR as SERENE SE HEE icra ve eb ves santana rv ES vent cease eet octane nae ect 20 52 15 Serre EE E Cs E ee ee A a EA ee eee ce AT ee ee ene ane emer T 20 52116 Screen AC CINE ie D 20 5 2 17 Screen TINS O UII ne ee ane eee en re PERS EENES 20 Deo BUT T E ER E Eee rer eee 20 e WU SEES EA EA TREE E EA 20 52 20 TIME D AEE AEEA OEE OAO 20 5 2 2 Bad Shutdown SAD a en ea a ee he e 21 92 22 PO SOON OO AN de te ee 21 De 23 Shitdo wn UMR ea da de de ee dt 21 5 2 24 PC restart minimum OFF HMS means ste sense nee mere nm te ta nent 21 5 2 25 PC OFF detection current threshold sense ae dm ee 21 5 2 26 PC OFF detection WIM CF 4 ane eee ae a ee ae on 21 92 27 WA PRESSER RER OR ee seas sten ENEDES REDER SE REE ERE TE ees ERE a REE ERE EEG RESENS IT EDR ERE EF ENE 21 5 2 28 Relay 2 BACKUP 0 cccccccesssccessseeesseecessseecseeeceseseeeeseeecssssecesseeecnseeecseasecessaeeceesseecssaeecesaseceesueeeeeasesessaeees 22 E ne 22 5 3 1 Firmware version ane eee eme ne em met 22 OO ed tn 22 Ne E na de ee D ne rca 22 5 34 Power ON cycles COUNTER are en chases sean er tee ee tierce wae ea eS 22 DCU20 User Manual rev 16 Page 3 29 ASE EEE tnnovative Interconnect and Interface Solutions 53 5 Operating NULL enken eres RENNER Use br son bre E E ASES 22 536 Battery installation CUS a ee ne eee et eee 22 5 37 Battery operating IMMO en ee ee ten a de ne ee ee rl rebel 23 54 LOGS RERO ER RE EN RP ER SR RSR ENTIER SR TER
18. e measured battery temperature exceeds the alarm threshold The threshold is the battery maximum temperature 5 2 10 Name Shortname Value ALARM BATTERY OVERTEMP END BOTE The maximum battery temperature reached during the alarm Description The measured battery temperature returns below the alarm threshold DCU20 User Manual rev 16 Page 26 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions Value Name Shortname Value ALARM BATTERY UNDERTEMP START BUTS Threshold temperature triggering the alarm Description o Description The measured battery temperature is lower than the alarm threshold The threshold is the battery minimum temperature 5 2 11 Name Shortname Value ALARM BATTERY UNDERTEMP END BUTE The minumum battery temperature reached during the alarm Description The measured battery temperature returns above the alarm threshold Name Shotname Value o ALARM BATTERY RI TOO HIGH START Ri high start Description The measured battery internal resistance exceeds the alarm threshold The threshold is the battery nominal internal resistance 5 2 8 maximal internal resistance variation 5 2 9 Name Shortname Value 000 i O ALARM BATTERY RI TOO HIGH END Ri high end Description The measured battery internal resistance returns below the alarm threshold Name Shortname Value ALARM_SHORT_CIRCUIT Description short circuit has been detected on the o
19. e screen to define the polarity and event associated with the relay gt Configure See 3 1 3 for more details Input nom volt Batt chemistry 5 3 Info While in the info menu use the UP DOWN KEY to navigate through the menu items 5 3 1 Firmware version inst date op time Shows the current firmware version Using the freely available POWERMASTER Eee software is possible to upgrade the firmware with the latest available version 5 3 2 Serial Batt op time FW version Shows the device serial number S N This serial number corresponds to the S N Serial shown on the device label gt Serial 5 3 3 Name Shows the device name Using the freely available POWERMASTER software is possible to modify the device name The default name is DCU 20 5 3 4 Power ON cycles counter Shows the Power ON cycles counter which is incremented by 1 every time the Boot cycles device is poweredON gt 3cycles Op time Batt inst 5 3 5 Operatingtime Shows the device operating time The counter shows the hours of operation device UMEME powered since the manufacturing gt Gh Batt inst date Batt op time 5 3 6 Battery installation date Boot cycles Op time Shows the battery installation date This value can be edited pressing the OK KEY EEE or using the wizard see 5 5 It is used by the system to calculate the battery gt 19 12 2812 operating time Batt op time FW version DCU20 User Manual rev 16 Pa
20. een after 1min of inactivity no key pressed The message can be removed pressing the Ee MENU KEY S 5 2 Settings The setting menu contains all the configurable parameters available to the user Use the UP DOWN KEY to navigate through the menu items Press the OK KEY to enter and exit the editing mode while in editing mode use the UP DOWN KEY to change the selected value DCU20 User Manual rev 16 Page 17 29 W W W ASI EZ COM innentive Interconnect and Interface Solutions 5 2 1 Input nominal voltage Relay 1 ready Relay 2 backup Used to set the nominal input voltage on the input connector Used to generate the EEE input under voltage and over voltage alarm See 6 for more details gt 24 8 Default 24V Batt chemistry Range 11V 28V Batt nom volt Resolution 0 1V 5 2 2 Battery chemistry Relay 2 backup Input nom volt Used to set the chemistry of the battery The system support Lead Acid Nickel and Er Lithium batteries For Lithium the battery pack used must include the protection and balancing circuitry nom Default Pb Capacity Choices Pb NiMh CC CV Lith CC CV 5 2 3 Battery nominal voltage Input nom volt Batt chemistry Used to set the nominal battery voltage Batt nom volt Default 24V gt 24 44 Range 11V 28V or input nominal voltage 20 Batt capacity Resolution 0 1V Batt cf alt 5 2 4 Battery capacity chemistry nom volt Used to set the nominal batt
21. een is shown at power ON It shows the device name serial number and firmware version Status This is the default view where the user can find the most relevant information about the device status The system always falls back to this view after 60s of inactivity no key pressed Settings All the device settings are configurable from this menu Use the UP DOWN KEY to navigate through the parameters Press the OK KEY to enter exit the editing mode In editing mode use the UP DOWN KEY to change the highlighted value Info Device information such asfirmware version serial number and device name is visible from this menu Logs All the alarms and event are logged in a circular buffer and visible from this screen Use the UP DOWN KEY to navigate through the logs Wizard The wizard helps the user to configure the system through a series of screens OCUZ8 DEMC 12345678 VE Self test 0k SETTINGS INFO LOGS WIZARD STATUS gt SETTINGS STATUS SETTINGS STATUS SETTINGS INFO STATUS SETTINGS Table 3 User interface layout DCU20 User Manual rev 16 W W W ASI EZ COM Date dd mm yyyy ime hh mm ss from volt ch volt inst date op time System Wizard Do you want to continue with he wizard Page 16 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions MENU KEY Scrolls betweenmenus ES DOWN KEY Scrolls down menus and values BEN UP KEY Scro
22. ery capacity of the battery The internal Coulomb jatt capacity counter uses this value to indicate the state of charge of the battery gt 2 84h Default 2Ah ch volt Range 1 2Ah 150Ah ba ELI Resolution 0 1Ah 5 2 5 Battery charge voltage nom volt Capacity Used to set the maximum voltage used to charge the battery See 3 6 for more Fire details Default 28 8V a eha CUPP deepdisch Range battery nominal voltage 33V or battery nominal voltage 40 Resolution 0 1V 5 2 6 Battery charge current capacity rer Vole Used to set the maximum current used to charge the battery See 3 6 for more att ch curr details gt 6 24 Default 0 2A deepdisch Range 0 2A 5A JKE Resolution 0 1A 5 2 7 Battery deep discharge voltage ch volt a Eha SUPP a Used to set the deep discharge voltage of the battery If the measured battery ESS voltage drops below this value the system disconnects it in order to prevent gt 15 9 irreversible damage nom Ri Default 18V max temp Range 8 2V battery nominal voltage 25 Resolution 0 1V DCU20 User Manual rev 16 Page 18 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 5 2 8 Battery nominal internal resistance ch curr Batt deepdisch Used to set the nominal battery internal resistance of the battery When set to En automatic the system will record the next valid measurement as the nominal value gt Disabled W
23. esistance measurement Without using the battery sense connection as shown in Figure 9 the AC voltage drop is measured across the battery connection terminals on the DCU20 The measured resistance will be in this case Rmeasured Ri Rcables When high Ah batteries and or small and long cables are used Rcables can be gt Ri Anyhow a connection problem as for example a loose contact can be detected by this measurement method By using the battery sense connection a Kelvin type connection as shown in Figure 10 the AC voltage drop is measured directly at the battery terminal In this case the measured resistance is exactly the battery internal resistance Ri independently on the cables length and size It is recommended to use this method to have an accurate reading of the battery internal resistance and thus an accurate prediction of the battery health status If the battery sense cables length is gt 2m it is recommended to twist the 2 wires together in order to increase the noise immunity 3 6 Battery charger The battery charger supports various chemistries such Lead Acid Nickel Lithium and every other battery chemistry assuming that the charging voltage and charging current values are provided by the battery manufacturer The charging algorithm is shown on Figure 8 Other charging algorithms can be implemented byrequest The user must set to the unit the following parameters to allow the charger to perform correctly e Battery chem
24. ge 22 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 5 3 Battery operating time Op time Batt inst date Shows the current battery operating time The value is calculated from the date entered in the battery installation date field Once the operating time exceeds the defined battery lifetime see 5 2 12 an alarm is generated see 6 5 4 Logs Every event is logged in the device FLASH memory From the log menu the user can view their history Use the UP DOWN KEYS to navigate between logs For each event the following information Is given Timestamp The time and date at which the event happened Event name The name identifying the event see 6 for the complete list of events Value The value may be empty See 6 for the detailed description of this field for each event 5 5 Wizard 16h64mi9s IUWE ee Ale The wizard assists the user during the DCU20 configuration The wizard should be run once at commissioning and every time the battery is replaced The wizard shows the following screens 1 The user must confirm with the OK KEY or use the MENU KEY to exit the wizard Exiting the wizard any time before the end leaves the configuration unchanged 3 Insert the battery chemistry and click next to confirm See 5 2 2 for more details 5 Insert the battery nominal capacity and click next to confirm See 5 2 4 for more details 7 Insert the battery charge current
25. hen set to disabled no alarm related to the battery internal resistance will be Patt max temp generated Batt lifetime Default Disabled Range 1mQ 300mQ Disabled Automatic Resolution 1mQ 5 2 9 Battery maximal internal resistance variation deepdisch o NOM Combined with the nominal internal resistance it defines the threshold for the att max Ri ALARM BATTERY RI TOO HIGH Default 200 ne Laup Range 20 300 litetime Resolution 1 5 2 10 Battery maximum temperature chemistry Eatt nom Ri An optional external temperature sensor P N WNTC 2MT is required Used to set ETES the maximum temperature at which the battery can operate safely If the measured gt sac temperature exceeds the set value an alarm is generated and the battery charging ee Een Max backup time is stopped until the return under normal temperature level Default 50 C Range 30 C 80 C Resolution 1 C 5 2 11 Battery minimum temperature deepdisch Batt nom Ri An optional external temperature sensor P N WNTC 2MT is required Used to set EBMER the minimum temperature at which the battery can operate safely If the measured gt 18 temperature is lower than the set value an alarm is generated and the battery Patt lifetime charging is stopped until the return under normal temperature level He e Default 10 C Range 20 C 0 C Resolution 1 C 5 2 12 Battery lifetime Batt nom Ri Batt max temp
26. hen the system is running on the Relay2 batteries SoC lt 25 LowBattery Active when the State of Charge SoC of the Unused battery is below25 Active when the battery life time counter is exceeding the value specified on 5 2 12 Battery Ri toohigh Active when the measured battery internal Relay 1 Se resistance Ri gt alarm threshold The threshold is me specified using setting 5 2 8 and 5 2 9 correctly specified on 5 2 7 Battery backup time left lt 25 Active when the remaining backup time is higher Unused than the 75 of the maximal backup time defined on 5 2 13 Activated by the PC shutdown and automatic restart function See 3 3 for details Table 1 Relays signals By default both relays polarity is set to NC Normal Close 3 2 Backup The system is in backup if the supply for the output is sourced from the battery input supply missing During backup the battery is monitored continuously to prevent over discharge see 5 2 7 A programmable backup timer see 5 2 13 is also implemented in order to fix a maximum backup time during power outages This allows preserving the battery life and shortening the recharge time avoiding discharging the battery when not needed During backup the internal Coulomb counter is used to give an estimation of the residual charge of the battery this information is given to the user on the LCD in form of remaining and through the ready relay which starts toggli
27. istry selectable between Lead Acid Nickel Lithium see 5 2 2 e Battery nominal voltage between 12V and 28V see 5 2 3 e Battery capacity between 1 2Ah and 150Ah see 5 2 4 e Battery charging voltage provided by the battery manufacturer see 5 2 5 DCU20 User Manual rev 16 Page 11 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions e Battery charging current provided by the battery manufacturer see 5 2 6 e Battery deep discharge voltage see 5 2 7 The battery charger automatically reduces the current to avoid exceeding the maximum input current 20A in case of high current load For example if the load is consuming 19A and the charger current is set to 3A the charger current is automatically reduced to 1A to avoid the 20A input current limit The charger voltage is independent on the input voltage power supply and is user settable Constant current Constant voltage Maintenance Voltage A User settable charge voltage A User settable charge current Current Time Figure 8 Battery chargingalgorithm The battery charge terminates in case at least one of the following conditions are satisfied e Low current The measured battery current is lower than 10 of the Battery charge current e Timer the charge is terminated after the battery has been charged for a predetermined amount of time The value is automatically calculated by the device For Nickel b
28. lls up menus and values Table 4 User interface keys The GUI is composed of 5 main menus which are selectable using the MENU KEY as shown on Table 3 The description of each menu is given below 5 1 Status The status screen shows the measurement and statuses to ease the system diagnostic The screen is divided in three main sections identified by the symbols shown below with the input the background color of the symbol changes from green to red message with the cause appears Output The measured output voltage and current is shown in this section In case of problems with the output the background color of the symbol changes from green to red and a message with the cause appears E Battery The battery voltage current temperature resistance and charge are shown in this Input The measured input voltage and current is shown in this section In case of problems section In case of problems with the battery the background color of the symbol changes from green to red and a message with the cause appears During charging and discharging the symbol background color changes to orange and the number of bars drawn inside reflects the charge status During discharging and charging an arrow drawn beside the symbol reflects the direction of the current flowing through the battery pointing towards the battery during charging Table 5 Status screen symbols Furthermore in case of problem a full screen alarm message appears on the scr
29. ng at 1Hz once the battery charge is lt 20 3 3 PC shutdown and automatic restart PC shutdown In case the DCU20 is used to supply a PC it is possible to automatically shut down the PC after an adjustable time of backup For this the PC must run the POWERMASTER application provided free and must be connected through USB Optionally POWERMASTER can call a task on the PC before shutting down for example to backup some sensitive data Automatic restart DCU20 is able to automatically restart a PC which was powered OFF by mistake for example in case of the Operating System OS crash The user may adjust an output current threshold and a timer used for detecting the PC OFF status In order to restart the PC the DCU20 toggles the output OFF and then ON again User must enable in the PC BIOS the automatic start in case of supply ON Note The DCU20 cannot interrupt the supply flow from the input to the output Therefore the user must use one of the DCU20 available relays by activating the PC OFF signal on it in order to enable automatic PC restart when the input supply is present The relay contact rated 2A 30Vdc must be wired in series to the device output using a 4A fast cartridge fuse Littlefuse 0217004 HXP or equivalent Be careful to respect maximum current rating of the fuse DCU20 User Manual rev 16 Page 8 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions In case the load PC current exceeds the DCU20 d
30. nput inhibits the BATTERY SENSE backup function this input is programmable to IN be active high or active low see 4 5 IN 6 Battery sense connection Used to El OUT accurately sense the battery voltage by ne considering the cables voltage drop It is recommended to use this input when the 2 saidi battery internal resistance measurement is SAE needed see 4 7 7 Input connection 2 poles are provided for input connection This must be connected to a power supply rated 12 28VDC with a maximum rated current of 20A see 4 2 8 Output connection 2 poles are provided for output connection It must be connected to the load to be backed up with a maximum rated current of 20A see 4 2 9 Battery connection 2 poles are provided for battery connection This must be connected to the battery Although the unit is protected please respect the correct polarity see 4 3 10 Display Input area provides information regarding the unit s input see 5 1 11 Display Output area provides information regarding the unit s output see 5 1 12 Display Battery area provides information regarding the battery see 5 1 13 Control keys 4 push buttons are provided to navigate through the menus and to select the various functions Figure 1 Front panel view DCU20 User Manual rev 16 Page 5 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 2 Features and benefits
31. onitor is composed of e Internal resistance Ri measurement The resistance is periodically measured The internal resistance is a good indicator of the battery health status a sudden increase of the internal resistance indicates a potential problem on the battery or on the battery wiring see 83 5 e Temperature T measurement The battery temperature is monitored through an optional temperature sensor P N WNTC 2MT The battery charger takes into account the battery DCU20 User Manual rev 16 Page 10 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions temperature and provides a temperature compensated charging voltage In case of over temperature the system disconnects the battery to prevent damage e Coulomb counter It allows having a quick estimation of the remaining battery capacity and consequently the available backup time e Deep discharge protection It protects against the deep discharge of the battery which can lead to its irreversible damage 3 5 Battery resistance measurement The battery internal resistance Ri is measured by injecting a defined AC current through a constant current source CCS in the battery and measuring the AC voltage drop across the battery terminals The principle is represented in Figure 7 The injected AC current I AC is flowing also through the cables connectors resistance Rcables Rcables Constant Current Source CCS Battery Figure 7 Internal r
32. ry contact rating the use of an external relay with suitable current voltage rating is needed relay coil voltage shall match output voltage It should be driven by the DCU20 internal dry contact OUTPUT D READY BACKUP D mner D INHIBIT k y READY BACKUP INHIBIT ON INHIBIT BATTERY SENSE D BATTERY SENSE EN BATTERY SENSE D BATTERY SENSE Fuse 5x 20 4A Fast IN IN IN IN OUT OUTPUT OUT OUTPU T OUT OUTPUT OUT BATTERY BATTERY BATTERY AE Figure 3 Internalrelay Figure 4 Externalrelay The diagram below shows the DCU20 behavior when Shutdown and automatic restart is enabled Input voltage ED Output voltage Output current E2 Es loff PC OFF signal Figure 5 Shutdown and restartchart Parameter Name Description Power failure on the line happens System enters backup mode E2 Automatic PC The POWERMASTER sends a shutdown commandto the PC shutdown Optionally a task is called before shutdown E3 Unexpected PC The PC shutdowns in an unexpected way for example caused by shutdown OS crash E4 PC restart DCU20 detect the PC being OFF because the output current was lower than loff current threshold for T4 time As a consequence DCU20 generates an ON gt OFF gt ON cycle on its output DCU20 User Manual rev 16 Page 9 29 Ar WWW ASI EZ COM tnnevative Intercannect
33. terconnect and Interface Solutions Value Name Shortname Value ALARM OUTPUT OVERLOAD START OOLS Threshold current triggering the alarm Description Description The measured output current exceeds the alarm threshold The alarm threshold is set to 22A Short name _ Value OL Z O ALARM OUTPUT OVERLOAD END OOLE The maximum output current reached during the alarm Description The measured output current returns below the alarm threshold Name Shortname Value ALARM BATTERY UNDERVOLT START BUVS Threshold voltage triggering the alarm Description The measured battery voltage is lower than the alarm threshold The threshold is 80 of the battery deep discharge voltage 5 2 7 Name Shortname Value ALARM BATTERY UNDERVOLT END BUVE The minimum battery voltage reached during the alarm Description The measured output current returns above the alarm threshold Name Shortname Value ALARM BATTERY OVERVOLT START BOVS Threshold voltage triggering the alarm Description The measured battery voltage exceeds the alarm threshold The threshold is the battery charge voltage 5 2 5 10 Name Shortname Value ALARM BATTERY OVERVOLT END BOVE The maximum battery voltage reached during the alarm Description The measured battery voltage returns below the alarm threshold Name Shortname Value ALARM BATTERY OVERTEMP START BOTS Threshold temperature triggering the alarm Description Th
34. tons DCU20 User Manual rev 16 Page 13 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 4 Installation A Warning In order to avoid potentially hazardous situations including fire hazard safety recommendations must be followed Only authorized staff can install the unit 4 1 Connecting the input to the power supply The DCU20 must be connected to a DC power supply rated between 12VDC and 28VDC with a maximum output current of 20A Use only 60 75 Class copper 1 5 2 5mm wires stripped 6 7 5mm The tightening torque must be 0 5 0 6Nm Please respect the wiring polarity Note The input current is equal to the load current plus the current needed by the battery charger to recharge thebattery Caution This input is designed to be connected ONLY to a short circuit protected power supply connecting a battery to this input or other DC sources with not defined current limitation may seriously damage the unit or the load and even result in fire hazard 4 2 Connecting the load The DCU20 must be connected to a DC load rated between 12VDC and 28VDC maximum 20A Use only 60 75 Class copper 1 5 2 5mm wires stripped 6 7 5mm The tightening torque must be 0 5 0 6Nm Please respect the wiring polarity Please check the load and the power supply are rating compliant 4 3 Connecting the battery The DCU20 must be connected to a battery with nominal voltage between 12VDC and 28VDC with up to 150Ah c
35. utput Short name _ Value DCU20 User Manual rev 16 Page 27 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 7 Technical Specifications INPUT SECTION Rated input voltage 11VDC 28VDC Operating range 10 29VDC Rated input current 20A No load power consumption BATTERY SECTION 12Vor24V pated DAKEN vallade Other voltages possible by request Lead Acid Battery chemistries Ni MH Ni Cd Li ION LiFePO4 BATTERY HEALTH MONITOR 1mQ 300mQ using Kelvin connection Coulomb counter Battery temperature through optional 10KQ NTC sensor Battery operating time since installation Number of cycles USER INTERFACE ON generic failure onthe system details onthe LCD ed LED pel iene blinking battery backup function active 2 dry contacts relays rated 30V 2A GENERAL NOTE specifications may change without notice in order to improve the product Physical dimensions Additional monitoring functions DCU20 User Manual rev 16 Page 28 29 W W W ASI EZ COM innovative Interconnect and Interface Solutions 115 DCU20 User Manual rev 16 Page 29 29
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