Bicker Elektronik UPSI-2406 User manual

User Manual UPSI-2406
Bicker Elektronik GmbH
Ludwig-Auer-Straße 23 |86609 Donauwörth·Germany
English
UPS SYSTEM
OPEN FRAME

UPSI-2406
Revision 1-1 2
Revision Directory
Date Change
17.08 .2021
Revision 0-1
Initial version
24.11.2021
Revision 1
Release version
09.02.2022
Revision 1-1
Chapter B3 included
Legend of used symbols
Symbol Description
Attention! Important hazard warning.
Do not dispose of in the domestic waste.
Warning of electrical voltage.

UPSI-2406
Revision 1-1 3

UPSI-2406
Revision 1-1 4
Input voltage 24 V DC (22.5…30 V)
Input current 7.5 A max.
Output voltage Normal mode: VIN– 0.5 VDC max. (depending on load)
Battery mode: 23.5 V DC
Output current 6 A nominal
Capacitive load 3000 µF (at start)
Charging method CC/ CV/CP
Protection Input: Reverse Polarity protection
Output: Overcurrent protection, short circuit protection
Interface USB, RS232, HID UPS
Possible battery technology LiFePO4, Supercaps (EDLC)
Ambient temperature Operating: -20…+70°C
Storage/Transport: -30…+70°C
Operating altitude ≤4000 m
Max. permitted humidity ≤95 % (at +25°C, no dew)
Dimensions W/ H / D 105 x 17 x 70.5 mm
(including connectors and highest components)
Weight 0.09 kg
Technical Data
A Brief specification
UPSI-2406
24 V DC / 6 A
 24 V DC USV (Open Frame version)
 Intelligent input current detection
 Regulated output voltage in battery mode
 Minimum load detection
 Power-fail timer function
 Relay dry contact on power fail
 Reboot function
 Fuel gauge
 Shutdown via external signal
 Battery start function

UPSI-2406
Revision 1-1 5
A Brief specification UPSI-2406 ............................................................................... 4
B Introduction and description ............................................................................... 6
B1 Description of the product and its functions ............................................................................................6
B2 Intended use .................................................................................................................................................................7
B3 UPS Gen2 Configuration Software....................................................................................................................7
C Safety instructions ................................................................................................ 8
D Technical Data ....................................................................................................... 9
D1 General Technical Data............................................................................................................................................9
D2 Drawing........................................................................................................................................................................... 16
E Name / Address / Support E-Mail / Phone number of the manufacturer ....... 16
F General Data ........................................................................................................ 17
F1 Installation advice.....................................................................................................................................................17
F2 Convection and installation position...........................................................................................................17
F3 Overview of connectors / interface...............................................................................................................18
F4 Description of connectors................................................................................................................................... 19
F5 Dimensioning the upstream power supply.............................................................................................22
F6 Connecting diagram...............................................................................................................................................23
F7 Initial operation.......................................................................................................................................................... 24
F8 Overview connector / Counterpart with description / Scope of delivery............................ 25
F9 Charging time............................................................................................................................................................. 25
F10 Reverse polarity / Overcurrent / Short circuit......................................................................................... 25
F11 Backup time in battery mode........................................................................................................................... 26
F12 Behaviour in case of exceeding maximum backup time................................................................26
F13 Battery start...................................................................................................................................................................26
F14 Status LED...................................................................................................................................................................... 27
F15 Shutdown diagram.................................................................................................................................................. 28
F16 Recommendations for a long UPS service life......................................................................................... 29
F17 Maintenance................................................................................................................................................................ 29
F18 Disposal...........................................................................................................................................................................29
F19 Disclaimer ......................................................................................................................................................................29
F20 Preventive measures and rules when operating the UPS system............................................. 30

UPSI-2406
Revision 1-1 6
B Introduction and description
Read carefully before initial operation!
This manual shall help the user to get familiar with the product and its components and features. It shall pro-
vide information as accurately and completely as possible.
The manual as well as all documents has to be read and followed strictly before installation. Otherwise in cer-
tain situations warranty and guarantee can be cancelled partly or completely. Any liability on the part of Bicker
Elektronik is excluded for possible existing errors as well as non-compliance with the instructions for use and
installation.
B1 Description of the product and its functions
The UPSI-2406 (hereinafter also called UPS) is a DC/DC UPS system with numerous digital features and high
performance. The UPS can be operated with different energy storage devices (hereinafter also called batte-
ry(s)), which are different in technology, capacity and chemistry. Only energy storage devices made by Bicker
Elektronik are to be used, due to the charging settings are made according the recognization of the used bat-
tery type. The primary use of the UPS is to secure the supply during power failures and/or voltage fluctuations.
The application which should be protected is connected to the output of the UPS.
The UPS requires a rated dimensioned power supply of 24VDC at the input. After the input voltage is applied,
the UPS works in normal mode automatically. The input voltage is passed through to the output and the
connected energy storage device is charged simultaneously. The charging current depends dynamically on
the load current at the UPS output. The green status LED lights up continuously when the UPS is in this state.
In the event of a voltage drop or a voltage fluctuation of the input voltage (below undervoltage limit),
the UPS is switched to battery mode (also backup mode). In this state, the application at the UPS output
is supplied via the energy storage device. The backup time (also buffer time) depends on the used ener-
gy storage, the value of the output current and the software settings of the UPS. An important feature is
that the output voltage in battery mode is always regulated to 23.5VDC and does not decrease as the
voltage of the energy storage device drops. If the UPS operates in battery mode, the status LED is slowly fla-
shing (1Hz flashing). When the UPS is used with LiFePO4 battery and it is discharged completely in battery
mode, the recharging has to happen as soon as possible.
When the input voltage returns, the UPS is automatically switched back to normal mode and charging of the
energy storage device is continued.
The UPS can also be used for user-initiated shutdowns of the supply voltage or cycles. Application examples
are the replacement of larger batteries in vehicles in which the electronics should continue to be supplied, the
opening and closing of safety valves after a malfunction or the shutdown of a system.

UPSI-2406
Revision 1-1 7
B2 Intended use
This device was developed for use as a built-in device in an end product with a housing and for professional
use in applicatons such as industrial control, communication and measurement technology. It must not be
used in devices or equipment where a malfunction will cause serious injury or endanger human life. The person
placing the product on the market or the user has to ensure that the end product complies with the required
standards and EMC directives.
The housing of the end product has to protect against electrical, water and fire hazards so that a indoor and
outdoor use is possible. The required safety distances between the individual sub-devices and components
have to be observed.
B3 UPS Gen2Configuration Software
UPS Gen Configuration Software is required for setting parameters and programming new firmware for all
UPSI Gen devices under Microsoft® Windows. The software tool also shows the operating status of the UPS
and its energy storage devices and can be connected to the device via USB:
The model has the native UPS device group integrated via USB / HID-UPS (HID Power Class). Most operating
systems (OS) recognize the UPSI models via Plug & Play without additional driver and can be used with the
operating system‘s own energy settings.
The UPS Gen2software tool offers additional setting options such as time-bound shutdown and other impor-
tant features.
The Software can be downloaded here
The User Manual for the Software can be downloaded here

UPSI-2406
Revision 1-1 8
C Safety instructions
WARNING!
Disregarding of following issues can result in electric shock, fire, serious injury or death.
1. Improper use and opening of the device will void the warranty.
2. The device may only be used as intended.
3. The national accident prevention and safety regulations must be observed.
4. The assembly of the device and the electrical installation have to be state of the art.
5. The electrical, thermal and mechanical limit values have to be observed.
6. The UPS wiring specifications - as described in this manual - have to be followed .
7. The end product has to comply with the necessary approvals and standards that are required for
the respective field of application.
ATTENTION!
1. Care must be taken to ensure proper and professional wiring.
2. The device pack must not be exposed to fire and temperatures outside the specification.
3. The device must not be immersed in water or exposed to splash water.
4. The device must not be operated in a humid environment or in an environment where dew and
condensation are to be expected.
5. The device must not be opened, short-circuited, reversed, overheated or otherwise soldered/welded .
6. Changes or attempts to repair the device are to be omitted.
7. Effects of foreign objects on the device must be avoided (e.g. metal parts).
8. Do not put obviously damaged devices into operation (e.g. dents, burn marks, rough contamination).
9. Keep ventilation openings clear.
10. Device must not be dropped.
11. All parts of the device and accessories must not be eaten or swallowed.
12. A current limited source is to be used. The required current values for the UPS are described
in this manual.
13. The UPS is supplied with voltage from both the input source and the energy storage. The latter is still
energized even after the input source has been disconnected.
14. The device is to be used as a built-in device or sub-device in an end product.

UPSI-2406
Revision 1-1 9
INPUT DATA – UPSI-2406
Unless otherwise stated, all specifications apply to 25°C ambient temperature,
24 V DC input voltage and nominal output current (IN).
Input voltage 24 VDC
Input voltage range 22.5 VDC…30 VDC
Electric strength max. 35 VDC
Fixed connect threshold
Undervoltage
Voltage drop Input/Output
22.5 VDC
0.5 VDC max. (depending on load)
Current consumption
IN(UN, IOUT = IN, ICHARGE = 0)
IMAX (UN, IOUT = ISTAT.BOOST, ICHARGE = max)
IDYN (UN, IOUT = IDYN.BOOST, ICHARGE = 0)
INO-LOAD (UN, IOUT = 0, ICHARGE = 0)
ICHARGE (UN, IOUT = 0, ICHARGE = max)
6.1 A
7.5 A
7.6 A
<100 mA
2.4 A
Power consumption
PN(UN, IOUT = IN, ICHARGE = 0)
PMAX (UN, IOUT = ISTAT.BOOST, ICHARGE = max)
PDYN (UN, IOUT = IDYN.BOOST, ICHARGE = 0)
PCHARGE (UN, IOUT = 0, ICHARGE = max)
146.5 W
180 W
182.5 W
58 W
Internal input fuse Yes (15 A)
Switch-on time <5 s
Switch-on time battery start (BS) <5 s
D Technical Data
D1 General Technical Data

UPSI-2406
Revision 1-1 10
OUTPUT DATA – UPSI-2406 (NORMAL MODE)
Unless otherwise stated, all specifications apply to 25°C ambient temperature,
24 V DC input voltage and nominal output current (IN).
Output voltage 24 VDC
Output voltage range UOUT = UIN – 0.5 VDC max. (depending on load)
Capacitive load 3000µF (at start)
Output current
IN
ISTAT.BOOST
IDYN.BOOST
ISFB
6 A
6.3A
6.4…7.5 A for max. 3s
30A (5ms)
Output power
PN(UN, IOUT = IN, ICHARGE = 0)
PSTAT.BOOST (UN, IOUT = ISTAT.BOOST, ICHARGE = 0)
PDYN.BOOST (UN, IOUT = IDYN.BOOST, ICHARGE = 0)
141.5 W
148.5 W
150…175 W for max. 3s
Short-circuit proof Yes
No-load proof Yes
Overcurrent shutdown 6.4…7.5 A for max. 3 s; 7.6…10.8 A for max. 100 ms;
>10.8 A for max. 5 ms
OUTPUT DATA – UPSI-2406 (BATTERY MODE)
Unless otherwise stated, all specifications apply to 25°C ambient temperature,
24 V DC input voltage and nominal output current (IN).
Output voltage 23.5 VDC
Output voltage range n.a.
Output current
IN
ISTAT.BOOST
IDYN.BOOST
ISFB
6 A
6.3 A
6.4…7.5 A for max. 3s
30A (5ms)
Output power
PN(UN, IOUT = IN, ICHARGE = 0)
PSTAT.BOOST (UN, IOUT = ISTAT.BOOST, ICHARGE = 0)
PDYN.BOOST (UN, IOUT = IDYN.BOOST, ICHARGE = 0)
140 W
147 W
149…175 W for max. 3s
Short-circuit proof Yes
No-load proof Yes
Overcurrent shutdown 6.4…7.5 A for max. 3 s; 7.6…10.8 A for max. 100 ms;
>10.8 A for max. 5 ms
Load current for battery start (BS) 6 A max. (tested with BP-LFP-1325, State of charge SOC ≥10 %)
Switching time normal mode >>battery mode <600µs

UPSI-2406
Revision 1-1 11
CONNECTION DATA INPUT / OUTPUT (X1)
Connection method Screwable plug connector
Conductor cross-section solid 0.129 mm…1.31 mm (26…16 AWG)
Conductor cross-section flexible 0.129 mm…1.31 mm (26…16 AWG)
Conductor cross-section with ferrule 0.129 mm…1.31 mm (26…16 AWG)
Stripping length 6 mm…7 mm
Tightening torque 0.3 Nm…0.4 Nm
BATTERY CHARGE UNIT
Charging method CC / CV / CP
End-of-charge voltage Depending on energy storage, app. 16 V max.
Charging current Depending on energy storage, 4.5…5.0 A, 16 A max.
Battery technology LiFePO4 / EDLC (Supercaps)
RELEASED ENERGY STORAGES
BP-LFP-1325 LiFePO4 / 13.2 VDC / 2.5 Ah / 33 Wh
BP-LFP-1375 LiFePO4 / 13.2 VDC / 7.5 Ah / 99 Wh
BP-SUC-1645 EDLC / 15.2 VDC / 6.8 kJ (4.5 kJ useful) /
1.89 Wh (1.25 Wh useful)
BP-SUC-16090 EDLC / 15.2 VDC / 13.5 kJ (9.0 kJ useful) /
3.75 Wh (2.5 Wh useful)
CONNECTION DATA – RELAY (X5)
Connection labeling RL
Switch contact (potential free) Relay
Status (configurable) Power Fail Alarm
Switching voltage 24 VDC / 125 VAC
Current carrying capacity 1A (DC) / 0.5 A (AC)
State - signal assignment NO (Normally Open) / NC (Normally Closed) –
configurable via Software (see UPS Gen2software manual)
Connection method Lockable plug connector
Conductor cross-section solid 0.205 mm…1.3 mm (24…16 AWG)
Conductor cross-section flexible 0.205 mm…1.3 mm (24…16 AWG)
Conductor cross-section with ferrule 0.205 mm…1.3 mm (24…16 AWG)
Stripping length 7 mm…9 mm
Switching time 1500 ms max.

UPSI-2406
Revision 1-1 12
DATA INTERFACE – USB (X6 OR X7)
Interface designation USB
Numbers of interfaces 1
Connection method USB type B (female) or pin header, pitch 2.54mm
Locking No
Transmission physics USB 2.0
Topology Point-to-point
Protocol VCOM, HID
Transmission length ≤3m
Access time <1s
Chipset NXP
Electrical isolation No
DATA INTERFACE – RS232 (X9)
Interface designation RS232
Numbers of interfaces 1
Connection method MicroMatch
Locking No
Transmission physics RS232 light (TX / RX)
Topology Point-to-point
Symbol rate (baud rate) 38400
Type of cable 1:1
Transmission length ≤10 m
Access time <1 s
Voltage level -6 VDC … +6 VDC
Electrical isolation No

UPSI-2406
Revision 1-1 13
GENERAL DATA
Flammability class according to UL 94 V0
Weight 0.09 kg
UPS connection in parallel No
UPS connection in series No
Protection type Non
Protection class III (without PE)
Mounting type Built-in device
Housing version Open Frame
Dimension W / H / D 105 mm / 17 mm / 70.5 mm
(including connectors and highest components)
ENVIRONMENTAL CONDITIONS
Ambient temperature (operation) -20… +70°C
Ambient temperature (start up without load) -30°C
Ambient temperature
(storage / transport)
-30… +70°C
Max. permitted humidity ≤95 % (at +25°C, no dew)
Operating altitude ≤4000m
Climate class 3k3 (EN 60721)
Degree of pollution 2
Overvoltage category
EN 61010-1
EN 61010-2-201
I
I
Indoor / Outdoor use Yes / Yes (end product has to be certified)
STANDARDS
Safety extra-low voltage IEC 61010-1 (SELV)
IEC 61010-2-201
APPROVALS
UL n.a.
CSA
CB Scheme

UPSI-2406
Revision 1-1 14
INTERFERENCE IMMUNITY ACCORDING TO EN 61000 (INDUSTRY)
Basic standard CE Fulfilled requirements according to EN 61000 (CE)
(Interference immunity of industrial environment)
Electrostatic discharge
EN 61000-4-2
Contact discharge
Air discharge
Comment
The end product has to be certified. The UPSI-2406 is de-
signed to meet all requirements according to CE. The manual
for the certified DIN rail version (UPSI-2406D) can be used as
a guideline for the limit values that can be achieved by the
device.
Electromagnetic HF field
EN 61000-4-3
Frequency range
Test field strength
Frequency range
Test field strength
Comment
Fast transients (Burst)
EN 61000-4-4
Test voltage
Comment
Surge voltage load (Surge)
EN 61000-4-5
Test voltage L–N
Test voltage L–PE, N–PE
Comment
Power frequency magnetic field immunity
EN 61000-4-8
Test level
Comment

UPSI-2406
Revision 1-1 15
EMISSION ACCORDING TO EN 55016-2-3 (DOMESTIC)
Basic standard CE Fulfilled requirements according to EN 55016-2-3 (CE)
(Domestic)
Conducted emission from the power port
EN 55016-2-3
Frequency range
Comment
The end product has to be certified. The UPSI-2406 is de-
signed to meet all requirements according to CE. The manual
for the certified DIN rail version (UPSI-2406D) can be used as
a guideline for the limit values that can be achieved by the
device.
Electric field radiated emission
EN 55016-2-3
Frequency range
Comment

UPSI-2406
Revision 1-1 16
D2 Drawing
68 mm
70,5 mm
105 mm
76,6 mm19,1 mm
3,1 mm
61,7 mm
4 x 3,20
17 mm
E Name / Address / Support E-Mail / Phone number of the manufacturer
Bicker Elektronik GmbH · Ludwig-Auer-Straße 23 · 86609 Donauwörth · Germany
E-Mail: [email protected] · Tel.: [phone]
Unless otherwise stated,
Tolerance according to:
DIN ISO 2768 T1 - m
DIN ISO 2768 T2 - K

UPSI-2406
Revision 1-1 17
F General Data
F1 Installation advice
Installation and operation of this device is only allowed to be executed by a qualified
electrician! The application has to be separated from any power during the mounting process.
Wires have to be connected safely and must not have contact with sharp edges. Pay attention
to correct polarity! Before commissioning, check all the connections for correctness!
F2 Convection and installation position
When installing in the overall system, it has to be ensured that
the required distances to neighboring parts and boards are main-
tained. Sufficient ventilation holes or open ventilation areas should
be provided during installation in order to avoid air congestion or
the like. The device can optionally be installed in the system with
suitable heat conducting pads (gap pad/gap filler) in order to com-
pensate for temperature increases of the components due to clo-
ser/narrow placement to neighboring components. This is recom-
mended on the bottom side in the area of the converter (choke L2,
Power MOSFETs Q10, Q110 and Q9) and in the input area (choke L1).
The functional grounding of the UPSI-2406 and UPSI-1208 is pro-
vided from version v10.0 on both the input side as well as on the
output side (VIN –and VOUT–). The connection takes place via the
mounting hole B03 next to the input / output connector X1. The
remaining three mounting holes (B01, B02 and B04) are isolated.
For PCBs with version v9.0 or lower, the functional grounding is
only connected on the output side (VOUT-) via the mounting holes
B04 (near USB socket X6) and B02 (near choke L1).
It is recommend installing the board vertically in the overall sys-
tem with the input/output socket X1 pointing upwards. This
installation position favors the heat dissipation of the circuit board
hot spots in the area of X1 and the converter.
The following distances to neighboring devices
are recommended:
Top side circuit board:
–>Neighboring component: 30 mm min.
Bottom side circuit board:
–>Neighboring component: 10 mm min.
Left/right:
–>Neighboring component: 5 mm min.

UPSI-2406
Revision 1-1 18
F3 Overview of connectors / interfaces
External Status LED
X2
RS232
X9
Input and output
X1
Battery Data
X4
Battery Power
X3
S1 Switch*
Relay
X5
Battery Start
X11
USB
X7
Temperature sensor
X12
(for internal purposes only)
X10
(for internal purposes only)
USB
X6
JP1
(for internal
purposes only)
*S1 Switch: (µC reset): Pressing it will reset the microcontroller to its initial state.
Use only in the event of an error (not in normal mode).

UPSI-2406
Revision 1-1 19
F4 Description of connectors
INPUT AND OUTPUT (X1)
PIN FUNCTION
1Vin +
2Vin –
3Vout –
4Vout +
Vin Vout
RS-232 (X9)
1
3
5
7
9
PIN FUNCTION
1Relay contact 1
2Relay contact 2
The function of the relay connection is configurable via software. When closing the relay the resistor
value between both contacts is approx. 0 , otherwise they are „open load“.
RELAY (X5)
43 2 1
+– – +
21
2
4
6
8
10
PIN FUNCTION
1PIN 8 ENABLE
2 DTR
3 TXD
4 NC
5 RXD
6 NC
7 DSR
8+5V (4.9V at 20mA /
4.6 V at 50mA)
9 GND
10 NC
To enable PIN 8, PIN 1 has to be
permanently switched to PIN 9 (GND).

UPSI-2406
Revision 1-1 20
PIN FUNCTION
1 GND
2GND (housing/shielding)
3 Data+
4 Data–
5 V+
USB (X7)
1 2 3 4 5
PIN FUNCTION
1 LED anode, V+
2LED cathode, V–
EXTERNAL STATUS LED (X2)
An external low-current LED can be connected to connection X2 (LED current 5…10mA).
2 1
PIN FUNCTION
1 Battery start, contact 1 (to µC)
2Battery start, contact 2 (GND)
BATTERY START (X11)
1
2