Amalgen 7021 Series User manual

Amalgen
Model 7021-7025
DC Backup UPS
Manual Revision 1
Model 7021 and 7025 Se ies
Amalgen Technologies Pty. Ltd.
43 Ande son oad Mo tdale NSW 2223 Aust alia
18/10/06 7021 and 7025_manual1.doc Page 1 of 7

DC Backup UPS Application, Maintenance and Installation Manual Revision 1
Manual Contents
1 Int oduction....................................................................................................................................... 2
2 P oduct ange.....................................................................................................................................2
3 Application........................................................................................................................................ 3
3.1 Sizing of UPS............................................................................................................................. 3
4 Technical desc iption.........................................................................................................................4
5 Monito ing.........................................................................................................................................5
6 Installation......................................................................................................................................... 6
7 Maintenance...................................................................................................................................... 6
8 Specification...................................................................................................................................... 7
1 Introduction
The Amalgen 7021 and 7025 se ies DC backup unit is an un-inte uptable powe supply, designed fo
situations whe e only 12VDC is equi ed. The 7021 and 7025 se ies is efficient and simple, allowing the
equipment to be p otected in a cost-effective way, and with high eliability. They p ovide the following
functions:
•Supply when AC mains is available
•Supply when AC mains has failed
•No-b eak changeove of powe when mains fails o etu ns
•Recha ge of batte y when AC etu ns (Amalgen batte y management system)
The above functions a e p ovided in a single unit designed to fit in 19 inch equipment acks. Impo tantly,
the unit fo ms a complete solution to the powe and backup powe needs. The efo e, the e a e advantages to
the installe and use . These a e:
•No need to do sepa ately mount batte ies
•No need to fo exte nal components to compensate tempe atu e fo batte y cha ging
•No need to fo any exte nal components
•No need fo any wi ing othe than load connection
2 Product range
The 7021 and 7025 se ies comp ises 2 units. The main featu es a e shown in the table below.
Model
numbe
Backup
capacity
Featu es Load cu ent
No m (su ge 20ms)
Ope ating
ange
7021 17AH
7025 40AH
Analog cont ol, full featu ed, basic telemet y 1A (5A) 0C-55C
2A (10A) 0C-55C
The base model offe s eliable powe with all p oduct featu es.
18/10/06 7021 and 7025_manual1.doc Page 2 of 7

DC Backup UPS Application, Maintenance and Installation Manual Revision 1
3 Application
Most equipment uses DC powe , even if it is connected to the AC mains. Ce tain types of equipment used in
p ocess cont ol, use only 12VDC, which is usually supplied by the AC main via a t ansfo me . The 7021 and
7025 se ies allows use s of this type of equipment to have “no-b eak” powe no matte what the condition of
the AC main. The use of the DC backup unit is shown below.
12VDC system supplied only f om AC mains and AC UPS
12VDC system supplied by 7021 and 7025 se ies back-up unit
Figu e 3
Figu e 3 (AC only supply) shows a load, which is suppo ted by a t aditional UPS. In ush cu ent and powe
facto of the load needs to be facto ed into the choice of UPS size. Getting the UPS matched to the load
(pa ticula ly in the small, p ice sensitive catego ies) is not st aightfo wa d. Then the e a e powe spikes and
load t ansients to conside . A DC back-up system is a good alte native.
The 7021 and 7025 back-up system p ovides answe s fo all the above:
•Rugged AC supply, ated to 55C ambient
•Load t ansient tole ant design
3.1 Sizing of UPS
Batte ies do not give thei full capacity at highe loads, highe tempe atu es o as they age. As discha ge time
gets smalle the available capacity is educed. The main equi ements a e Amps equi ed and backup time.
•Amps: The cu ent equi ed by the load in Amps.
•Time: The amount of time equi ed fo the powe to be supplied to the load so that it can function well.
Numbe of hou s o pa t the e of. Use the typical, Batte y Available Ah Output cha t (figu e 3.1) Please
consult batte y manufactu es specifications as data may va y f om this cha t.
18/10/06 7021 and 7025_manual1.doc Page 3 of 7
AC
UPS
System
powe
supply
12VDC
load
7021 and
7025
se ies DC
backup
12VDC
load

DC Backup UPS Application, Maintenance and Installation Manual Revision 1
Calculation example: 2 Amps backup is equi ed fo 8 hou s.
a) Multiply Amp x Hou s (8 x 2 = 16). This gives 16Ah s. Nea est size DCUPS would be 17Ah s.
b) Look at Figu e 3.1. The discha ge time, in this case 8 H s, shows that app ox. 90% of the 17Ah will be
available f om a fully cha ged batte y
c) Check: 17 * 0.9 = 16 app oximately so this unit will just satisfy the load
The cu ve above shows the p obable available Ampe e-hou capacity fo va ying time pe iods ove which
the batte y is d ained. This is fai ly indicative of comme cially available sealed lead acid batte ies.
Figu e 3.1
4 Tec nical description
Model 7021 and 7025 is a 12volt (nominal) DC powe -supply with batte y backup. An AC ectifie supplies
powe to the load and doubles as a batte y cha ge . The e a e 3 modes of ope ation:
•AC powe available. In this mode, the load is supplied f om the AC ectifie . The batte y is cha ged at a
constant voltage but with cont olled cu ent. The mal compensation is p ovided to ensu e that the batte y
eceives optimum cha ge.
•AC fail condition. In this mode, the inte nal 12volt lead acid batte y supplies the load. Batte y voltage
and unbalance a e monito ed. Low batte y is flagged as an ala m.
•Ove -cu ent condition. In this mode, the inte nal batte y can supply peak cu ents to the load fo sho t
pe iods. The batte y fuse limits the amount of ove -cu ent. Sustained high cu ent will cause the fuse to
open.
Changeove f om AC to DC is done elect onically without b eak in supply to the load. In AC available
mode, the batte y is cha ged automatically.
18/10/06 7021 and 7025_manual1.doc Page 4 of 7

DC Backup UPS Application, Maintenance and Installation Manual Revision 1
The main components of the 700x se ies a e shown in the following block diag am.
AC in
Figu e 4
7021 and 7025 se ies Block diag am
5 Monitoring
Analog monito ing
The status of the unit is indicated on the f ont panel, and emotely, via voltage-f ee contacts. The following
table shows the details.
CONDITION LOCAL (LEDs) REMOTE (RELAYs)
Cha ge OK G een light if OK N/O contact closes if OK
DC available G een light if Vload ove 18VDC -
Low Voltage ala m Red light if Vbatt is unde 20VDC N/O contact opens on low batte y
18/10/06 7021 and 7025_manual1.doc Page 5 of 7
Linea DC
powe
supply
Lead acid
batte y
(fused)
Monito ing and
cont ol unit
Changeove switch
and low voltage
disconnect ci cuit
Use load
connection
Telemet y

DC Backup UPS Application, Maintenance and Installation Manual Revision 1
6 Installation
Fit this unit in locations whe e pe sonnel access is est icted. Pe sonnel with access must be t ained in
elect ical safety and be familia with p ocedu es fo avoiding elect ical shock.
Allow oom in 19 inch ack fo ai flow a ound case.
Wi ing
AC input Unit must be connected to mains ea th.
P ovide exte nal p otection, as t ere is no AC fusing inside unit.
DC output DC output wi ing size should comply with wi ing codes.
We ecommend 1.5mm up to 17Ah, 2.5mm fo 40Ah. (keep wi ing sho t)
Connection of the output is f om te minal block, ma ked + E --.
To install as ea thed supply connect output + o – to ea th.
To install as a floating supply, connect two 10k/1/2W esisto s exte nal to the
unit(see diag am). Fit one esisto f om g ound to + te minal and the othe f om
g ound to the – te minal.
Batte ies Units a e shipped without batte ies. On commissioning, check that the fuse is
emoved and connect the batte ies as follows:
1/ connect RED wi e to +ve te minal of batte y 1.
2/ connect BLACK wi e to –ve te minal of batte y 2.
3/ Fit fuse.
Replacement of batte ies follows the same p ocedu e.
Remote
monito ing
Remote wi ing should be 0.75mm sq.
Wi ing plugs into f ont of unit. The voltage-f ee contacts a e clea ly labelled.
Connections fo emote monito ing a e given in the table below.
Connecto pin
numbe
Function - Analog ve sion
Relay contacts
6 connecto top Common c arger monitor
5 Closed fo cha ge OK, opens on fail
4 Open fo OK, closes on fail
3 Common battery low
2 Closed fo batt OK, opens on low
1 Open fo OK, closes when low
Mounting dimensions fo the 7021 and 7025 ange of DCUPS a e given in the attached d awing.
7 Maintenance
The e is no outine maintenance equi ed on the 7021 and 7025 se ies DC backup units. Howeve , it is
ecommended that the batte y capacity be ve ified yea ly with a non-c itical load, to ensu e adequate
pe fo mance du ing powe outages.
18/10/06 7021 and 7025_manual1.doc Page 6 of 7
WARNING: Take care when inserting batteries, as the batteries contain hazardous energy levels
Do not allow battery terminals to connect in a short circuit..

DC Backup UPS Application, Maintenance and Installation Manual Revision 1
Batte y life depends on batte y type, actual use and ave age tempe atu e. Long life batte ies will last 10
yea s, whilst standa d batte ies will last 3-5 yea s. Batte y sizes and types a e given below:
UPS capacity (batt weight each) Batte y dimensions (HxWxD) Batte y types
Powe sonic/Powe block
17Amp-hou (6.3kg) 19 inch ack x 2U x 170 PS12170 / PB12170
40Amp-hou (14kg) 19 inch ack x 4U x 170 PS12400 /PB12380
8 Specification
Design type DC UPS with integ al cha ge and elect onic changeove .
AC input Voltage 240VAC Nominal
Rated Cu ent See Below
AC Fusing To be p ovided exte nal to unit
IP ating IP20
DC Voltage 12VDC Nominal (9V to 14) Output is floating f om ea th
Cu ent The cu ent atings of diffe ent models given below
Cha ge Type Constant voltage (temp. compensated)
Recha ge time 10 hou s
Physical Model Wide High Deep Weight*
7021 17A 19 inch ack 2U 170mm 12 kg
7025 40A 19 inch ack 4U 170mm 24 kg
The mal Natu al convection, 55C max ambient
Allow 100mm a ound sides
Monito ing
Fo details see table
Local LEDs Cha ge OK (DC supply is OK)
DC Available
Batte y low ala m
Contacts fo Cha ge OK (AC on and cha ge OK)
Remote ala m Batte y voltage low when batte y is 10VDC
Stays ON until cut-off (9VDC) is eached
(contacts ated 50VDC/1A, 120VAC/0.5A)
EMC Compliance Radiated AS1044:1995 (amdts 1,2)
C-tick app oved
18/10/06 7021 and 7025_manual1.doc Page 7 of 7