Bicker Elektronik UPSI-2406D User manual

English
Bicker Elektronik GmbH
Ludwig-Auer-Straße 23 |86609 Donauwörth·Germany
User Manual UPSI-2406D
UPSI SYSTEM
DIN RAIL

UPSI-2406D
Revision 1 2
Revision Directory
Date Change
16.07.2020
Revision 0-1
Initial version
12.01.2022
Revision 1
Release version
Legend of used symbols
Symbol Description
Attention! Important hazard warning.
Do not dispose of in the domestic waste.
Warning of electrical voltage.

UPSI-2406D
Revision 1 3

UPSI-2406D
Revision 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 36 x 120 x 100 mm ±0.5 mm
(without front connectors and DIN-Rail mounting bracket)
Weight 0.25 kg
Technical Data
A Brief specification
UPSI-2406D
24 V DC / 6 A
 24 V DC UPS (DIN rail 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

UPSI-2406D
Revision 1 5
A Brief specification UPSI-2406D ............................................................................ 4
B Introduction and description ............................................................................... 6
B1 Description of the product and its functions ............................................................................................6
B2 Intended use .................................................................................................................................................................7
C Safety instructions ................................................................................................ 8
D Technical Data ....................................................................................................... 9
D1 General Technical Data............................................................................................................................................9
D2 Drawing........................................................................................................................................................................... 17
E Name / Address / Support E-Mail / Phone number of the manufacturer ....... 17
F General Data ........................................................................................................ 18
F1 Assembly and installation advice...................................................................................................................18
F2 Convection and installation position...........................................................................................................18
F3 Description of connectors................................................................................................................................... 20
F4 Dimensioning the upstream power supply.............................................................................................22
F5 Connecting diagram...............................................................................................................................................23
F6 Initial operation..........................................................................................................................................................24
F7 Overview connector / Counterpart with description / Scope of delivery............................ 25
F8 Charging time............................................................................................................................................................. 25
F9 Reverse polarity / Overcurrent / Short circuit.........................................................................................25
F10 Backup time in battery mode........................................................................................................................... 26
F11 Behaviour in case of exceeding maximum backup time................................................................26
F12 Status LED...................................................................................................................................................................... 27
F13 Shutdown diagram.................................................................................................................................................. 28
F14 Recommendations for a long UPS service life......................................................................................... 29
F15 Maintenance................................................................................................................................................................ 29
F16 Disposal........................................................................................................................................................................... 29
F17 Disclaimer ......................................................................................................................................................................29
F18 Preventive measures and rules when operating the UPS system............................................. 30

UPSI-2406D
Revision 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-2406D (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 (1 Hz 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-2406D
Revision 1 7
B2 Intended use
This device is designed to be installed into a suitable enclosure which protects against electrical, water and fire
hazards and can then be used indoors and outdoors. It is primary built for being mounted on a DIN Rail and
is intended for professional use in applications 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.

UPSI-2406D
Revision 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.
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.

UPSI-2406D
Revision 1 9
INPUT DATA – UPSI-2406D
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 V DC
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)
6.1A
7.5A
7.6A
<100mA
2.4A
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) n.a.
D Technical Data
D1 General Technical Data

UPSI-2406D
Revision 1 10
OUTPUT DATA – UPSI-2406D (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 3000 µF (at start)
Output current
IN
ISTAT.BOOST
IDYN.BOOST
ISFB
6 A
6.3 A
6.4…7.5A for max. 3s
30 A (5 ms)
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…175W 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-2406D (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
Switching time normal mode >>battery mode <600µs

UPSI-2406D
Revision 1 11
CONNECTION DATA INPUT / OUTPUT
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. 16V max.
Charging current Depending on energy storage, 4.5…5.0 A, 16 A max.
Battery technology LiFePO4 / EDLC (Supercaps)
RELEASED ENERGY STORAGE
BP-LFP-1325D LiFePO4 / 13.2 V DC / 2.5 Ah / 33 Wh
BP-LFP-1375D LiFePO4 / 13.2 VDC / 7.5 Ah / 99Wh
BP-SUC-1645D EDLC / 15.2 VDC / 6.8 kJ (4.5 kJ useful) /
1.89 Wh (1.25 Wh useful)
BP-SUC-16090D EDLC / 15.2 VDC / 13.5 kJ (9.0 kJ useful) /
3.75 Wh (2.5Wh useful)

UPSI-2406D
Revision 1 12
CONNECTION DATA – RELAY
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.
DATA INTERFACE – USB
Interface designation USB
Numbers of interfaces 1
Connection method USB type B (female)
Locking No
Transmission physics USB 2.0
Topology Point-to-point
Protocol VCOM, HID
Transmission length ≤3 m
Access time <1s
Chipset NXP
Electrical isolation No

UPSI-2406D
Revision 1 13
DATA INTERFACE – RS232
Interface designation RS232
Numbers of interfaces 1
Connection method DSUB 9-Pin (female)
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
GENERAL DATA
Flammability class according to UL 94
(housing / terminal blocks)
V0
Weight 0.25 kg
UPS connection in parallel No
UPS connection in series No
HOUSING
Degree of protection IP 20
Protection class III (without PE)
Mounting type DIN-Rail mounting (EN 60715)
Housing version Aluminium
Dimension W / H / D 36 mm / 120 mm / 100 mm ±0.5 mm
(without front connectors and DIN-Rail mounting bracket)

UPSI-2406D
Revision 1 14
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 ≤4000 m
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 (in housing)
STANDARDS
Safety extra-low voltage IEC 61010-1 (SELV)
IEC 61010-2-201
APPROVALS
UL n.a. (possible upon consultation)
CSA
CB Scheme

UPSI-2406D
Revision 1 15
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
4 kV
8 kV
Criterion B
Electromagnetic HF field
EN 61000-4-3
Frequency range
Test field strength
Frequency range
Test field strength
Comment
80 MHz … 1 GHz
10 V/m
1.4 GHz … 2 GHz
3 V/m
Criterion A
Fast transients (Burst)
EN 61000-4-4
Test voltage
Comment
2 kV
Criterion A
Surge voltage load (Surge)
EN 61000-4-5
Test voltage L–N
Test voltage L–PE, N–PE
Comment
±0.5kV
±1kV
Criterion A
Power frequency magnetic field immunity
EN 61000-4-8
Test level
Comment
30A/m
Criterion A

UPSI-2406D
Revision 1 16
LEGEND
Criterion A Normal operating behaviour within the defined limits.
Criterion B Temporary impairment of the operating behaviour, that is
corrected by the device itself.
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
150kHz–30MHz
Conform
Electric field radiated emission
EN 55016-2-3
Frequency range
Comment
30MHz–1GHz
Conform

UPSI-2406D
Revision 1 17
120 mm
36 mm
100 mm
8.5...9 mm
29.4 mm
D2 Drawing
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-2406D
Revision 1 18
The devices comply with the IP protection class 20.
F General Data
F1 Assembly and 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
For this DIN rail version, vertical mounting on a horizontal rail (DIN rails according to EN 60715) is recommen-
ded in order to achieve the best possible convection of the UPS. Another mounting position is possible, but
operation up to +70°C ambient temperature can not be guaranteed.
Make sure that no ventilation holes are covered by other, neighboring components and devices.
The following distances to neighboring devices are recommended:
Left / right: 20 mm
Top / bottom: 50 mm

UPSI-2406D
Revision 1 19
DIN-Rail mounting and DIN-Rail profile according to EN 60715

2.

3.  4.

1.
Push down

UPSI-2406D
Revision 1 20
F3 Description of connectors
PIN FUNCTION
1Vin +
2Vin –
3Vout –
4Vout +
RS-232
RELAY CONNECTION (RL)
PIN FUNCTION
1Relay contact 1
2Relay contact 2
21
INPUT & OUTPUT (IN & OUT)
Vin
Vout
+– – +
43 2 1
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“.
To enable PIN 9, PIN 1 has to be
permanently switched to PIN 5 (GND). PIN FUNCTION
1PIN 9 ENABLE
2 TXD
3 RXD
4 DSR
5 GND
6 DTR
7 NC
8 NC
9+5V (4.9V at 20mA /
4.6 V at 50mA)