Angst+Pfister nextys DCU20 User manual

DCU20 User Manual rev. 19
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DCU20
12/24V 20A High Performance DC-UPS
User Manual
POWERMASTER
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DISCLAIMER
NEXTYS reserves the right to make changes without further notice to any products herein. NEXTYS
makes no warranty, representation or guarantee regarding the suitability of its products for any
particular purpose, nor does NEXTYS assume any liability arising out of the application or use of any
product, and specifically disclaims any and all liability, including without limitation consequential or
incidental damages. “Typical" parameters which may be provided in NEXTYS data sheets and/or
specifications can and do vary in different applications and actual performance may vary overtime. All
operating parameters, including “Typicals", must be validated for each customer application by
customer's technical experts. NEXTYS does not convey any license under its patent rights nor the
rights of others. NEXTYS products are not designed, intended, or authorized for use as components in
systems intended for surgical implant into the body, or other applications intended to support or
sustain life, or for any other application in which the failure of the NEXTYS product could create a
situation where personal injury or death may occur. Should Buyer purchase or use NEXTYS products
for any such unintended or unauthorized application, Buyer shall indemnity and hold NEXTYS and its
officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs,
damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim
of personal injury or death associated with such unintended or unauthorized use, even if such claim
alleges that NEXTYS was negligent regarding the design or manufacture of the part.
The Customer should ensure that it has the most up to date version of the document by contacting its
local NEXTYS office. This document supersedes any earlier documentation relating to the products
referred to herein. The information contained in this document is current at the date of publication. It
may subsequently be updated, revised or withdrawn.
The Customer should ensure that NEXTYS product uses the most up to date Software and Firmware
provided on NEXTYS website to ensure reliable operation of the system.
All Trade Marks recognized. Specifications and information herein are Subject to change without
notice.
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TABLE OF CONTENTS
1System description...........................................................................................................................................5
2Features and benefits.......................................................................................................................................6
3Functional description ......................................................................................................................................7
3.1 Remote monitoring and controlling.............................................................................................................7
3.1.1 USB......................................................................................................................................................7
3.1.2 Digital input...........................................................................................................................................7
3.1.3 Dry contact outputs ..............................................................................................................................7
3.2 Backup........................................................................................................................................................8
3.3 PC shutdown and automatic restart ...........................................................................................................8
3.4 Battery health monitor...............................................................................................................................10
3.5 Battery resistance measurement..............................................................................................................11
3.6 Battery charger.........................................................................................................................................11
3.7 Coulomb counter ......................................................................................................................................12
3.8 Cold start ..................................................................................................................................................13
4Installation ......................................................................................................................................................14
4.1 Connecting the input to the power supply ................................................................................................14
4.2 Connecting the load..................................................................................................................................14
4.3 Connecting the battery .............................................................................................................................14
4.4 Connecting the temperature sensor.........................................................................................................14
4.5 Connecting the INHIBIT input...................................................................................................................15
4.6 Dry contacts..............................................................................................................................................15
4.7 Battery sense connection .........................................................................................................................15
5User interface.................................................................................................................................................16
5.1 Status........................................................................................................................................................17
5.2 Settings.....................................................................................................................................................17
5.2.1 Input nominal voltage.........................................................................................................................18
5.2.2 Battery chemistry ...............................................................................................................................18
5.2.3 Battery nominal voltage......................................................................................................................18
5.2.4 Battery capacity..................................................................................................................................18
5.2.5 Battery charge voltage.......................................................................................................................18
5.2.6 Battery charge current........................................................................................................................18
5.2.7 Battery deep discharge voltage .........................................................................................................18
5.2.8 Battery low voltage.............................................................................................................................19
5.2.9 Battery nominal internal resistance....................................................................................................19
5.2.10 Battery maximal internal resistance variation.................................................................................19
5.2.11 Battery maximum temperature .......................................................................................................19
5.2.12 Battery minimum temperature ........................................................................................................19
5.2.13 Battery lifetime................................................................................................................................19
5.2.14Maximum backup time....................................................................................................................20
5.2.15 Inhibit polarity..................................................................................................................................20
5.2.16 Screen contrast...............................................................................................................................20
5.2.17 Screen backlight .............................................................................................................................20
5.2.18 Screen timeout................................................................................................................................20
5.2.19 Buzzer state....................................................................................................................................20
5.2.20 Date.................................................................................................................................................20
5.2.21 Time................................................................................................................................................21
5.2.22 PC shutdown enable.......................................................................................................................21
5.2.23 PC shutdown delay.........................................................................................................................21
5.2.24 PC shutdown time...........................................................................................................................21
5.2.25 PC restart minimum OFF time........................................................................................................21
5.2.26 PC OFF detection current threshold...............................................................................................21
5.2.27 PC OFF detection timer..................................................................................................................21
5.2.28 Relay 1 (Ready)..............................................................................................................................22
5.2.29 Relay 2 (Backup) ............................................................................................................................22
5.3 Info............................................................................................................................................................22
5.3.1 Firmware version................................................................................................................................22
5.3.2 Serial..................................................................................................................................................22
5.3.3 Name..................................................................................................................................................22
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5.3.4 Power ON cycles counter...................................................................................................................22
5.3.5 Operating time....................................................................................................................................22
5.3.6 Battery installation date......................................................................................................................23
5.3.7 Battery operating time........................................................................................................................23
5.4 Logs..........................................................................................................................................................23
5.5 Wizard.......................................................................................................................................................23
6Events and Alarms .........................................................................................................................................24
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1 System description
Use latest device Documentation, Software and Firmware to ensure reliable operation of
the system (downloadable from www.nextys.com).
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 unit is
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
monitoring and controlling. Firmware update is
also possible through USB connection.
3. Temperature sensor connection: Used to
connect a temperature sensor (P/N: WNTC-
2MT) to measure the battery temperature for
protection and temperature compensated
charge method.
4. Relays dry contacts: 2 relays are present for
remote monitoring. See §3.1 for more details.
5. Inhibit input: A signal between 5VDC and
30VDC applied to this input inhibits the
backup function; this input is programmable to
be active high or active low (see §4.5).
6. “Battery sense”connection: Used to
accurately sense the battery voltage by
considering the cables voltage drop. It is
recommended to use this input when the
battery internal resistance measurement is
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.
1
2
3
4
5
6
7
8
9
10
11
12
13
Figure 1: Front panel view
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2 Features and benefits
The main features are:
Integrated battery charger for multi-chemistry batteries with charging current up to 5A.
Automatic sensing of input voltage, load current and battery current.
Protections against battery reverse polarity connection and over current when operating
from the battery.
Battery “health monitoring”system: measuring battery internal resistance, battery
temperature and providing a Coulomb counter.
User settable maximum backup time.
Remote input to inhibit the UPS function.
Connection of a battery thermal sensor (optional).
Integrated data logger with time stamp: all events / errors are logged in the internal memory
and downloadable through the USB interface.
Automatic PC shutdown/restart function (see §3.3)
Embedded user interface:
4 buttons and 1 color graphic CSTN LCD, Displays the set-up, status, measures and
alarms
Online device configuration.
USB port for remote monitoring and configuration.
Dry contacts for status monitoring
“POWERMASTER”PC application:
Connection through USB interface.
Remote monitoring and configuration.
Firmware upgrade.
Same functionalities of the embedded user interface with the ease of the PC benefits.
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3 Functional description
A simplified block diagram of the DCU20 is shown in Figure 2.
1
1
2
2
3
3
4
4
5
5
6
6
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7
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8
D D
C C
B B
A A
DC-UPS_V0.1.SchDoc
Title
Size
Date
File
DocumentNumberRevision
Sheetof
Drawn By
DCU20 - 20A 12/24V DC-UPS Simplified Block Diagram
A3 doc_number V0.1
11
Marco Geri
11/07/2012
NEXTYS
V
A A
V
V
A
Reverse
Polarity
Batteryhealth
Monitor
5ABattery
Charger
Microprocessor
Buttons Relays
USB
Thermal
Display
Buzzer
OUTIN
BATT
THR
USB
READY
BACKUP
Figure 2: DCU20 simplified block diagram
DCU20 is a high performance digitally controlled DC-UPS that can be used in any DC system with a
rated voltage between 12V and 28Vand 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
a minimum.
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 (available
for download at www.nextys.com) which allows the full control and monitoring of the DCU20 unit with
the ease of the PC.
3.1.2 Digital input
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 §5.2.15).
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:
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Name
Description
Default setting
Backup
Active when the system is running on the
batteries.
Relay 2
SoC < 25% (Low Battery)
Active when the State of Charge (SoC) of the
battery is below 25%.
Unused
Battery life time expired
Active when the battery life time counter is
exceeding the value specified on §5.2.13
Relay 1
Battery Ri too high
Active when the measured battery internal
resistance (Ri)> alarm threshold. The threshold is
specified using setting §5.2.9 and §5.2.10.
Relay 1
Battery failure
Active when the battery could not be charged
correctly.
Relay 1
Battery under voltage
Active when the battery voltage is below the value
specified on §5.2.7
Unused
Battery backup time left < 25%
Active when the remaining backup time is higher
than the 75% of the maximal backup time defined
on §5.2.14
Unused
PC OFF signal
Activated by the PC shutdown and automatic
restart function. See §3.3 for details.
Unused
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 §5.2.14) 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 toggling at 1Hz once the battery charge is < 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.
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In case the load (PC) current exceeds the DCU20 dry 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.
Fuse 5x20
4A Fast
OUTPUT+
OUTPUT-
Figure 3: Internal relay
OUTPUT+
OUTPUT-
Relay
Figure 4: External relay
The diagram below shows the DCU20 behavior when Shutdown and automatic restart is enabled.
Time
PC OFF signal
PC status
Output voltage
Output current
Input voltage
T1 T2 T3
... ... T4 T3
E3
E1
E2
E4
Ioff
Figure 5: Shutdown and restart chart
Parameter
Name
Description
E1
Backup
Power failure on the line happens. System enters backup mode.
E2
Automatic PC
shutdown
The POWERMASTER sends a shutdown command to the PC.
Optionally: a task is called before shutdown.
This event is triggered by the “PC shutdown delay”(§5.2.23) or
“Battery low alarm”(§5.2.8), whatever comes first.
E3
Unexpected PC
shutdown
The PC shutdowns in an unexpected way, for example caused by
OS crash.
E4
PC restart
DCU20 detect the PC being OFF because the output current was
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lower than Ioff current threshold for T4 time. As a consequence
DCU20 generates an ON->OFF->ON cycle on its output.
T1
PC shutdown delay
User settable (§5.2.23). Time between start of backup and start of
PC shutdown procedure.
T2
PC shutdown time
User settable (§5.2.24). 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 restart minimum
OFF time
User settable (§5.2.25). T3 is the delay used between the return
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->OFF->ON cycle to restart.
T4
PC OFF detection
timer
User settable (§5.2.27). Minimum time at which the output current
must be below the Ioff current threshold to trigger the automatic
PC restart (PC supply ON->OFF->ON cycle).
Ioff
PC OFF detection
current threshold
User settable (§5.2.26). Current threshold used to detect PC OFF
status. This value must be lower than the minimum PC current
consumption when this is ON.
Table 2: Shutdown and restart
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” check box.
Figure 6: PC shutdown settings
3.4 Battery health monitor
The battery health monitor is composed of:
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
§3.5).
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