Operating Instructions “AKKUTEC 2410”
Contents
1. N33G1D02 050203 en 20A a Eden tei EE tose ro CE d S woare io CE E 900 00 00 oo Bott Tt Bott Tr d CS Netzbetrieb H Se Wetzbetrieb 1 Fehler i Fehler d 0 EL ES D gt Batt c ay c ey EH EH Eat EH eF B lager eF B ex K CU IG CU EI 1 Bd Cu Eu bd Ex E a7 E EI E Ei ajj a Gi GI eas E nik Dap At bat T m Bott N N N nal Z k L So 21 Un o Ua Item Label PRO loas O A F Adresse Helmholtzstrasse 13 D 77652 Offenburg Postfach 2327 N 77R12 Offanhiira 2 can result in irreparable damage to the AKKUTEC module possible to the set of batteries for safety reasons Tel 49 0 781 206 0 Fax 49 0 781 25318 www j schneider de info i schneider de 9 10 Gesch ftsf hrer Karl Schneider Dipl Ing FH Bettina Schneider Dipl Betriebswirt BA Rolf Anti Dipl Wirt Ing FH Amtenaricht Offanhiiran HRR 7RR 24V DC battery circuit contactor with switching current gt 30A DC Free wheeling diode for battery circuit contactor Attention Never operate the contactor without a free wheeling diode Ope2. gt oh A 2 ef ll pw N L prom il 8 Nove x DE Fah 8 z PFC x LEAD ACID BATTERY drive and control X lt FFeoutotor E Loy CURREN SHARE BUS curcuit a S 8 l 4 20mA 3 BATT TEMP OPTION isolation barrier M D lt d ele SHUT DOWN oe ee F B0DST CHARGE Leos gt t EB 30V nen CENERAL ERROR N F L K EEDA E a 30V DC 0 5A AINS OPERAT ION d T DISPLAY OPERATION AND DIS AYPANEL E I OTTONE Z lt a 0 20mA BATTERYCURRENT MEA IRMENT 5 OPTIONAL J K LEDS A 5 53 30V DC 0 59 UBATT ABOVE L K LEDY S 2 30V DC 0 5A BA ITHIN 4 10 Subject to technical change Adresse Gesch ftsf hrer g Enipo Ki Helmholtzstrasse 13 D 77652 Offenburg Postfach 2327 N 77812 Offanhiira Tel 49 0 781 206 0 Fax 49 0 781 25318 www j schneider de info i schneider de Karl Schneider Dipl Ing FH Bettina Schneider Dipl Betriebswirt BA Rolf Anti Dipl Wirt Ing FH Amtenaricht Offanhiira HRR 7452 Ss lt p S SS S I Ra oS Ren Nr 27AN J Schneider Elektrotechnik GmbH N33G1D02 050203 6 Placing In Operation The unit is switched on by the application of the mains supply The battery voltage must match the nominal voltage of the charging rectifier Never reverse the poles of the battery Never short circuit batteries Ri
3. Component Label Protection of the battery circuit 1 and battery circuit 2 Attention The protection components overload and short circuit protection are to be installed as close as possible to the set of batteries for safety reasons G1 G2 Backup batteries F1 F2 Adresse Helmholtzstrasse 13 D 77652 Offenburg Postfach 2327 N 77812 Offanhiira Decoupling diode module Attention The decoupling diode module must be designed for the sum of both AKKU7EC output currents 10 20 A Overload short circuit current AKKUTEC module with special parameter settings as Redundant Module 1 ID code 0 as well as Redundant Module 2 ID code 1 The complete sampling of the signal inputs and outputs is performed separately See also Section 3 4 For the connections for the Control and Display Panel please refer to the appropriate handbook Tel 49 0 781 206 0 Fax 49 0 781 25318 www j schneider de info i schneider de 10 10 Gesch ftsf hrer Karl Schneider Dipl Ing FH Bettina Schneider Dipl Betriebswirt BA Rolf Anti Dipl Wirt Ing FH Amtenaricht Offanhiiran HRR 7RR Subject to technical change a EN iso oth a Sy om Ren Nr 27AN
4. 1kg d 7 0Ah Battery Set 5 7kg e 12 0Ah Battery Set 9 2kg Storage Temperature Permissible 0 50 C Operating Temperature battery life 4 Installation The battery backed up DC power supply is to be installed such that the necessary cooling is provided A minimum separation of gt 75mm to neighbouring equipment or assemblies in the area of the v entilation openings is to be maintained The installation is always to be made such that sufficient air circulation through the unit can be ensured All fastening points are always to be used to fix the unit During installation the unit is to be covered in the case that swarf from drilling can fall on or in the unit Risk of short circuit 3 10 Subject to technical change Adresse Gesch ftsf hrer Ba EN iso soor _ Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH L web Nets D 77652 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA ei Ris Postfach 2327 www j schneider de Rolf Anti Dipl Wirt Ing FH Qos N 77612 Offanhiira info i schneider de Amtenaricht Offanhiira HRR 7RR Ren Nr 27AN J Schneider Elektrotechnik GmbH 5 Connection Prior to connection the values for the mains voltage and frequency are to be checked against the values on the rating plate Connect in accordance with the labels on the connecting terminals See main block diagram and connector assignment
5. EL EE oll E SG ele H e S N A eg Il iy ELA P a 60 0 325 0 S08 340 0 Einboutiefe 175mm Einbautiefe 183 mounting depth 175mm mounting depth 1B3mm Installation depth not in type high cluding terminals depth including terminals Adresse Helmholtzstrasse 13 D 77652 Offenburg Postfach 2327 N 77R12 Offanhiira Tel 49 0 781 206 0 Fax 49 0 781 25318 www j schneider de info i schneider de 7 10 Gesch ftsf hrer Karl Schneider Dipl Ing FH Bettina Schneider Dipl Betriebswirt BA Rolf Anti Dipl Wirt Ing FH Amtenaricht Offanhiira HRR 7RR Subject to technical change Ge ebHets KE mee Ren Nr 27AN J Schneider Elektrotechnik GmbH N33G1D02 050203 10 Battery Replacement Baitery replacement is only permitted to be performed by authorised service personnel Battery replacement is to be performed as follows Battery removal Take out of operation as described in Section 8 Remove 3 pin Combicon battery connector on the AKKU TEC Undo the 2 fixing bolts on the battery retai
6. The unit is taken out of operation by removing the mains supply To prevent subsequent backup from the batteries the battery circuit must be opened by activating Shut Down See Section 7 4 The Netzbetrieb Mains Operation and Fehler Fault LEDs must go out Never undo electrical connections whilst the unit is in operation It also not permitted to make electrical connections whilst the unit is in operation 6 10 Subject to technical change Adresse Gesch ftsf hrer E BE a _ Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH L web Nets D 77652 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA oN ei Ris Postfach 2327 www j schneider de Rolf Anti Dipl Wirt Ing FH Qo N 77612 Offanhiira info i schneider de Amtenaricht Offanhira HRR 7RR Ren Nr 97AN J Schneider Elektrotechnik GmbH 9 Installation Draw ings N33G1D02 050203 J U 9 J o o ES AKKUTEC P i AKKUTED JE wate ge AC d W Aum d H P SEE a en bes EE iI 09 E OO OO dy Cl CH E LU US f bg WP Se wl wo L 4 D s 10 Ge in o p E oo my SI NEN m N So H S a Arar i wimi CH B el cas El EI E Ei EI ein S H Si E yl ZE le etl
7. 2011 21 Lead Accumulator Maintenance Free 12V 12Ah 452011 22 15A FK2 Fuse 42041 6 7 5A FK2 Fuse 42041 4 13 Special Operating Modes The AKKUTEC is suitable for master slave operation as well as for redundant operation The required operating mode is defined by the setting of the parameters in the unit and the external circuit see below The parameters in the AKKU7EC units are set with the aid of the Control and Display Panel optional module via the O 2 interface If no control panel is available at the user the modules can also be purchased with the parameters set appropriately in the factory The parameters set can be seen on the additional label on the front of the module 8 10 Subject to technical change Adresse Gesch ftsf hrer E BE a _ Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH L web Nets D 77652 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA ei Ris Postfach 2327 www j schneider de Rolf Anti Dipl Wirt Ing FH Qos N 77612 Offanhiira info i schneider de Amtenaricht Offanhiira HRR 7RR Ren Nr 27AN J Schneider Elektrotechnik GmbH 13 1 Example Circuit for Master Slave Operation Increased Power Al MASTER d A2 SLAVE ENEE te GK w aas PFD 98 SER 24 i
8. 300 AC 15 4107 Va PF 0298 EEN E Be d ni trad CE Ae SYSTEM2 J N wt A SD out Metz We 2420 Lem p PRL 230 AC 15 41 D eg PF D 98 8 7 fre N33G1D02 050203 pm E Jo as joe ea ri E we Wen ts f e E e 2 GI ae 2 i GI aa CH E CH E CH JE CH JE DCS Er JE e Ac E Chr W I J CH JE J CH E a Eo s II CH JE CH CH II e CH E A Seene Elek trotechnit Gab J Schneider Elektrotechmit Groh D 77652 Di terborg D 77852 Di terborg D D N D we s w kak Sch ln Ua In the case of overload the DC output current comprises the maximum charging rectifier current as well as the current from the battery To prevent overload of the DC output circuit the circuit is to be protected externally Value see Section 3 1 The connections labelled 2 on the O 2 interface are connected internally with Ua To avoid the creation of earth loops the connections labelled 2 on 10 2 must not be connected together A connection here can result in damage to the AKKU TEC units
9. J Schneider Elektrotechnik GmbH N33G1D02 050203 Operating Instructions AKKU TEC 2410 NBPA 2410 N33G1 Placing in operation and maintenance only by suitably qualified personnel The operating instructions are to be read prior to usage or installation of the AKKU TEC the information given is to be observed In the case of failure to observe the information given all rights under the warranty may be lost Safety Instructions Power supply for protection class and enclosure rating IP20 Operation only in dry rooms Observe applicable VDE regulations in particular VDE 0100 and EN 60204 In front of the unit a separation must be installed at the input side To switch the unit at the output side voltage free both energy sources mains and battery must be separated The surrounding air temperature range is to be observed To prevent overload of the DC output circuit the circuit is to be protected externally with a fuse Value see Section 3 1 Only the battery types specified for the unit are permitted to be used Battery replacement is only to be made with the unit unpowered See Section 10 On the connection of external backup batteries battery protection must be provided by the user In this case the protection components overload and short circuit protection must be installed as close as possible to the set of batteries for safety reasons On the usage of batteries sufficient air flow in accor
10. dance with VDE 0510 part 2 must be ensured Never connect together new and used batteries or batteries of different types or from different manufacturers Dispose of used batteries in an environmentally responsible manner 1 Concise Description The battery backed up DC power supply in the AKKU7EC range uses the standby parallel principle of operation and in conjunction with a lead accumulator ensures that the DC power supply is reliably maintained in the case of a mains power failure The power supply has the following features Switched primary switched power supply with I V charging characteristic Active power factor correction PFC Microcontroller based battery management Temperature compensation for charging voltage by means of external sensor module optional module Display and control panel for switch cupboard door installation or surface mounting option 1 10 Subject to technical change Adresse Gesch ftsf hrer Ba EN iso soor VaN Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH eet D 77652 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA D Ru www j schneider de Rolf Anti Dipl Wirt Ing FH Ke Postfach 2327 N 77612 Offanhiira info i schneider de Amtenaricht Offanhiira HRR 7RR Ren Nr 27AN J Schneider Elektrotechnik GmbH As standard the following equipment versions are available Equipment Designat
11. dis charge limit unnecessarily it is possible to shut down battery operation early This is performed by applying a 24V DC control voltage to connection 3 on the IO 1 terminal strip 5 10 Subject to technical change Adresse Gesch ftsf hrer E BE a _ Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH L web Nets D 77652 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA ei Ris Postfach 2327 www j schneider de Rolf Anti Dipl Wirt Ing FH Qos N 77612 Offanhiira info i schneider de Amtenaricht Offanhiira HRR 7RR Ren Nr 27AN J Schneider Elektrotechnik GmbH N33G1D02 050203 7 5 Temperature Compensation optional module Lead batteries have a temperature coefficient of approx 4mV per C and cell The AKKUTEC final charging voltage is selected such that battery charging is provided over a temperature range of 15 40 C In applications with frequent and large temperature variations the charging vo ltage should be appropriately compensated to achieve optimal battery life Also particularly in the case of very low surrounding air temperature Tu lt 15 C compensation should be performed to ensure adequate battery charging By connecting the external temperature sensor module option to terminal strip IO 1 connection 1 and 2 note poles temperature compensation is automatically activated For an surrounding air temperature va
12. enance free Efficiency 230V Version 88 68 Fuse Protection Battery Load Circuit Secondary 2410 Type of Connector Combicon screw terminal Primary 2 5mm Netz Mains Type of Connector 2 Combicon screw terminal Secondary 2 5mm Ua Batt 2 Type of Connector Combicon screw terminal Interface 1 5mm 1O 1 10 3 Type of Connector Spring loaded terminal Ua 26 4V DC la 20A and Current Share Bus CS __ 0 5mm Ue 230V AC 1 If the case of FK2 fuse you have to use the values in Max Power Loss 44W brackets worst case 2 10 Subject to technical change Adresse Gesch ftsf hrer FA EN 180 Ki Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH Y ebHets D 77652 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA y Ru Rolf Anti Dipl Wirt Ing FH Cums Amtenaricht Offanhiira HRR 7RR Ran Nr 27AN S gt Postfach 2327 www j schneider de N 77612 Offanhiira info i schneider de J Schneider Elektrotechnik GmbH N33G1D02 050203 3 2 Indicators Netzbetrieb Mains Green LED Fehler Fault Red LED Operation LED illuminates on LED illuminates on e Mains operation i e e Battery operation Ue gt UEmin and Netzbetrieb Mains Operation LED goes Green LED out in this case Battery voltage within the e Us fault monitoring window i e e Battery circui
13. ion Comments Nominal Nominal Input Output Voltage Voltage NBPA 2410 0 N33G1M01 Standard unit individual module 81440 6 230V AC 24V DC NBPA 2410 0 N33G1S01 Special parameter settings individual NBPCN33G1S01 230V AC 24V DC module NBPC 2410 4 N33G1M03 Standard unit on mounting plate 4 Ah NBPCN33G1M03 230V AC 24V DC NBPC 2410 7 N33G1M01 Standard unit on mounting plate 7 Ah NBPCN33G1M01 230V AC 24V DC NBPC 2410 12 N33G1M02 Standard unit on mounting plate 12 Ah NBPCN33G1M02 230V AC 24V DC 2 Standards and Regulations Safety of power transformers power supply units and similar EN61558 2 17 VDE 0570 2 17 Particular requirements for transformers for switch mode power supplies Optocouplers for protective separation against electric shock requirements tests EN 61000 3 2 and EN61000 3 3 limit class A EN50082 2 1995 EN 50178 EN 60950 3 1 Electrical Data N33G1D02 050203 Rated Input Voltage 230V AC 47 63Hz Earth Leakage Current Fuse Protection Primar 2 5A slow internal 230 VAC 15 10 Max Series Fuse 5A slow 2410 1 4A Fuse Protection DC 1 Max Switch On Current 35A 2ms Output Circuit Output Voltage a 19 8 26 4V DC 2410 b 19 8 28 6V DC 15A 10A slow during activated boost charging or temperature compensation 26 4V DC 0 4 VV DIN 41773 1 Deep Discharge 19 8V DC 0 4 Protection and Load Shedding at 10A DC 1 05 1 1XlaNom Battery Type Pb battery maint
14. ning strap hold battery during this process Undo electrical connections on battery Remove battery Battery installation Installation is performed in the reverse order of removal as described above It is to be ensured that the battery poles are connected correctly In the case of batteries connected with the poles reversed battery charging and battery enable during mains failure is inhibited this is indicated by the simultaneous illumination of the Netzbetrieb Mains Operation and Fehler Fault LEDs Never short circuit batteries Risk of arcing and burns Never connect together new and used batteries or batteries of different types or from different manufacturers The correct retention of the batteries is to be checked after refitting Used batteries are to be disposed in an environmentally responsible manner 11 Maintenance To ensure adequate backup capacity of the power supply the capacity of the batteries should be checked at regular intervals of 3 to 6 months Checking the battery Force battery operation by switching off the mains The batteries must achieve the required bridging time under nominal conditions When the deep discharge limit is reached the AKKUTEC switches off automatically The unit is to be cleaned at least once a year depending on the degree of soiling 12 Spare Parts Spare Part 1 Lead Accumulator Maintenance Free 12V 4Ah 452011 42 Lead Accumulator Maintenance Free 12V 7Ah 45
15. on 7 2 Battery Test During mains operation a cyclic battery test loads the battery whilst the voltage is measured In this way it is possible to evaluate the quality of the battery A seriously aged battery is indicated by the simultaneous illumination of the Fehler Fault and Netzbetrieb Mains Operation LEDs centralised fault indication The battery test is used to detect seriously aged batteries To evaluate the backup capacity of the batteries with this system it is imperative that a manual battery check is performed from time to time See Section 11 7 3 Boost Charging In exceptional cases it may be required to boost charge lead batteries During this process the final charging voltage and thus also the output voltage is increased from 26 4V to 28 6V Boost charging is activated by applying a 24V DC control voltage to connection 4 on the IO 1 terminal strip and remains activated until the control voltage is removed again Boost charging results in the operation of the batteries in the gassing area and can be used to reactivate deep discharged or sulphated batteries The boost discharge mode should only be used on open non maintenance free batteries and must only be performed for a limited period The usage of boost charging in conjunction with closed maintenance free batteries is not permitted as here damage can be caused to the batteries 7 4 Shut Down To avoid discharging the backup batteries to the deep
16. ration without a free wheeling diode Fuse protection for battery circuit contactor Battery circuit protection Attention The protection components overload and short circuit protection are to be installed as close as AKKUTEC module with standard parameter settings The complete sampling of the signal inputs and outputs is performed via the master module See also Section 3 4 For the connections for the Control and Display Panel please refer to the appropriate handbook AKKU TEC module with special parameter settings as Slave Module The centralised fault indication signal from the slave module should be evaluated separately Selective fault localisation In the case of the master slave configuration the internal battery reverse pole connection protection is ineffective Reverse connection of the battery results unavoidably in damage to the loads and the AKKU7EC units To exploit the maximum effectiveness from the active current distribution the Ua cabling between the two modules should be made as symmetrical as possible cable length cable cross section Subject to technical change a EN iso oth a Sy om Ren Nr 27AN 13 2 Example Circuit for Redundant Operation Increase in the System Reliability EN SYSTEM1 Q d AKKUTEC Metz 3 Hh McP 2420 emm Im 2
17. riation of 0 40 C the final charging voltage and thus also the output voltage varies over a range of 27 3 26 2 VDC Battery temperatures above 45 C are indicated by the simultaneous illumination of the Fehler Fault and Netzbetrieb Mains Operation LEDs To obtain satisfactory battery life the operating temperature of the batteries should not exceed 20 C Higher temperatures lead to a drastic reduction in the life 7 6 Control and Display Panel optional module can be connected to AKKU TEC equipment using the option interfaces O 2 and IO 3 Particularly in larger battery system it is often desired to display equipment parameters e g battery voltage load current battery current error messages etc and to make parameter settings To meet these requirements a special door mounting display and control panel is available This panel has an illuminated LC display and a keypad setting parameters and operation The panel is connected to the IO 2 interface using two cables 7 7 Battery Current Measurement optional module can be connected to AKKU TEC equipment using the option interfaces O 2 and IO 3 To measure the battery current charging and discharging current an appropriate current measurement transducer is required that is inserted in the battery cable With the aid of the Control and Display Panel described in Section 7 6 the battery current can then also be indicated on the display 8 Taking Out of Operation
18. s Unused connecting terminal screws are to be tightened Connection Mains Input Voltage DC Output loads Pb Battery Battery Temperature Sensor optional module Current Share Bus in case of parallel connection of several modules Control Input Signal Contact Fehler Fault JN rol Input Shut Down Cont Starkladung Boost Charging Ua CS 1 10 1 3 Terminal Connecting terminal Netz Mains L N Connecting terminal Connecting terminal Batt Connecting terminal 10 1 1 2 Connecting terminal 3 CH Operation Within Connecting terminal Connecting terminal Connecting terminal Signal Contact Netzbetrieb Mains N33G1D02 050203 Connecting terminal 10 1 8 9 Centralised fault indication 10 1 5 NC 6 NO 7 COM 10 2 1 2 optional module 10 3 1 2 Above 10 3 3 4 Signal Contact Battery Voltage Connecting terminal 10 3 5 6 In the case of overload the DC output current comprises the maximum charging rectifier current as well as the current from the battery To prevent overload of the DC output circuit the circuit is to be protected externally Value see Section 3 1
19. sk of arcing Check the connections for correctness prior to switching on for the first time Only make electrical connections with the unit unpowered 7 Operation Approx 2s after the switch on of the mains the output voltage is enabled and the loads connected supplied with power The back up battery is also charged This operating mode is indicated by the illumination of the gree n Netzbetrieb Mains Operation LED By removing the mains voltage or if the input voltage drops below the minimum the AKKU TEC switches over to battery mode The battery mode is indicated by the illumination of the Fehler Fault LED The Netzbetrieb Mains Operation LED is not illuminated in this case The illumination of an LED always results in the energisation of the corresponding signal relay See block diagram Section 5 The Fehler Fault LED has a centralised fault indication function The individual causes of malfunctions are described in Section 3 2 7 1 Battery Circuit Monitoring To check the capability of the UPS to provide back up the battery circuit is tested cyclically at intervals of 60s the first test is performed 60s after mains switch on By means of this test it is possible to identify an open circuit or the high resistivity of the battery circuit A defective battery circuit is indicated by the simultaneous illumination of the Fehler Fault and Netzbetrieb Mains Operation LEDs centralised fault indicati
20. t open or 21 6 lt Ugat lt 27V DC high resistance test Green LED interval 60s Battery voltage above e Battery weak the monitoring window e Battery poles reversed i e Ugan 27V DC e Battery over temperature only in conjunction with temperature compensation 3 3 Operation Connection IO 2 External display and control panel for the display of operating parameter s and for setting option interface the device parameters option 3 4 Signal Inputs and Outputs Netzbetrieb Mains Operation Floating relay contact normally open max contact load 30V DC 0 5A Fehler Fault Floating relay contact changeover max contact load 30V DC 0 5A i Floating relay contact normally open max contact load 30 V DC 0 5A CC Floating relay contact normally open max contact load 30 V DC 0 5A Shut Down Shut down of the UPS mode Switched input referenced to earth switching level 24V DC 16 80V DC Starkladung Boost Charging Activation of boost charging boost charging voltage 28 6V DC Switched input referenced to earth switching level 24V DC 16 80V DC 1 The signal contacts are coupled to LEDs see Section 3 2 The illumination of an LED thus results in the energysation of the corresponding relay 3 5 General Weight 2410 Permissible 0 40 C a Individual Module 1 6kg 2405 Permissible 0 55 C b Mounting plate version 3 0kg Enclosure Rating IP20 without batteries See Section 9 c 4 0Ah Battery Set 5
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