Bicker Elektronik UPSI-2406DP3 User manual

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

UPSI-2406DPx
Revision 1-5 2
Revision Directory
Date Change
31.03.2020
Revision 0-1
Initial version
10.06.2020
Revision 1
Release version
03.07.2020
Revision 1-1
Chapter B2 extended,
Chapter B3 Environmental condition extended,
Chapter C1 Input data Internal input fuse changed
Chapter C1 Environmental conditions extended.
16.07.2020
Revision 1-2
PELV indication removed
12.08.2020
Revision 1-3
Chapter B3 Intended use more detailed specied
Chapter C1 Environmental conditions more detailed specied
(Indoor/Outdoor)
Page 2, Warning „Read User Manual“ at explanation „Legend of used
symbols“ supplemented
25.11.2020
Revision 1-4
Model UPSI-2406DP3 integrated
21.10.2021
Revision 1-5
Basic revision of individual chapters, updated backup time diagrams, B
rebuilt, E14 software removed, F9 rebuilt, F12 status LED rebuilt, new image
in F5, E5 images removed, F13 Shutdown diagram added
Legend of used symbols
Symbol Description
Attention! Important hazard warning.
Do not dispose of in the domestic waste.
Warning of electrical voltage.

UPSI-2406DPx
Revision 1-5 3

UPSI-2406DPx
Revision 1-5 4
Input voltage 24 V DC (22.5…30 V)
Input current 4.9 A max.
Output voltage Normal mode: VIN– 0.5 V DC max. (depending on load)
Battery mode: 23.5 V DC
Output current 4 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
Battery technology DP1: Li-Ion 2.5 Ah / 37 Wh
DP2: EDLC 5.73 kJ (3.88 kJ useful) / 1.59 Wh (1.08 Wh useful)
DP3: LiFePO4 2.5 Ah / 33 Wh
Ambient temperature Operating Storage/Transport
DP1: 0…+50°C DP1: -20…+50°C
DP2: -20…+65°C DP2: -30…+65°C
DP3: -20…+55°C DP3: -30…+55°C, recommended state of charge 80%
Operating altitude ≤4000 m
Max. permitted humidity ≤95% (at +25°C, no dew)
Dimensions W/ H / D 63 x 120 x 100 mm ±0.5 mm
(without front connectors and DIN-Rail mounting bracket)
Weight 0.6 kg (DP1 and DP2), 0.8 kg (DP3)
Technical Data
A Brief specification
UPSI-2406DP1 / -DP2 / -DP3
24 V DC / 4 A
 24 V DC UPS (DIN-Rail version)
 Integrated Li-Ion batteries (DP1) OR
Supercaps (DP2) OR LiFePO4 battery (DP3)
 Up to 500cycles (DP1)|up to 500000 cycles (DP2)|
up to 6 000 cycles (DP3)
 Capacity DP1: 37 Wh | DP2: 5.73 kJ | DP3: 33 Wh
 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-2406DPx
Revision 1-5 5
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*Backup time depends on battery capacitance, load and temperature. At very high or low temperatures a reduction of backup time occurs.
Unless otherwise specified, the values apply to measurements at +25 °C
Backup time* UPSI-2406DP2
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Backup time* UPSI-2406DP1
Pout [W]
Backup time [min]
Backup time [sec]
Pout [W]

UPSI-2406DPx
Revision 1-5 6
*Backup time depends on battery capacitance, load and temperature. At very high or low temperatures a reduction of backup time occurs.
Unless otherwise specified, the values apply to measurements at +25 °C
Backup time* UPSI-2406DP3
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50
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Pout [W]
Backup time [min]

UPSI-2406DPx
Revision 1-5 7
A Brief specification UPSI-2406DP1 / UPSI-2406DP2 / UPSI-2406DP3 ................ 4
B Introduction and description ............................................................................... 8
B1 Description of the product and its functions ............................................................................................8
B2 Intended use .................................................................................................................................................................9
C Safety instructions .............................................................................................. 10
D Technical Data ..................................................................................................... 11
D1 General Technical Data......................................................................................................................................... 11
D2 Drawing........................................................................................................................................................................... 20
E Name / Address / Support E-Mail / Phone number of the manufacturer ....... 20
F General Data ........................................................................................................ 21
F1 Assembly and installation advice................................................................................................................... 21
F2 Convection and installation position...........................................................................................................21
F3 Description of connectors................................................................................................................................... 23
F4 Dimensioning the upstream power supply.............................................................................................24
F5 Connecting diagram...............................................................................................................................................25
F6 Initial operation.......................................................................................................................................................... 26
F7 Overview connector / Counterpart with description / Scope of delivery............................ 27
F8 Charging time............................................................................................................................................................. 27
F9 Reverse polarity / Overcurrent / Short circuit ........................................................................................27
F10 Backup time in battery mode........................................................................................................................... 28
F11 Behaviour in case of exceeding maximum backup time................................................................28
F12 Status LED...................................................................................................................................................................... 29
F13 Shutdown diagram.................................................................................................................................................. 30
F14 Recommendations for a long UPS service life......................................................................................... 31
F15 Maintenance................................................................................................................................................................ 31
F16 Disposal...........................................................................................................................................................................31
F17 Disclaimer ......................................................................................................................................................................31
F18 Preventive measures and rules when operating the UPS system............................................. 32

UPSI-2406DPx
Revision 1-5 8
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-2406DP2, UPSI-2406DP2 and UPSI-2406DP3 (hereinafter also called UPS) are DC/DC UPS systems
with numerous digital features and high performance. Die UPS combines the UPSI-2406 with an integrated
energy storage: The UPSI-2406DP1 uses an energy storage with Lithium-ion technology, the UPSI-2406DP2
uses an energy storage with supercap (also EDLCs) technology and the UPSI-2406DP3 uses an energy storage
with LiFePO4 technology. 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
integrated 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 UPSI-2406DP3 (with LiFePO4 battery) is used 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-2406DPx
Revision 1-5 9
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-2406DPx
Revision 1-5 10
C Safety instructions
WARNING!
Disregarding of following issues can result in electric shock, fire, serious injury or death.
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.
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!

UPSI-2406DPx
Revision 1-5 11
INPUT DATA – UPSI-2406DP1 / UPSI-2406DP2 / UPSI-2406DP3
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)
INO-LOAD (UN, IOUT = 0, ICHARGE = 0)
ICHARGE (UN, IOUT = 0, ICHARGE = max)
4.1 A
4.9 A
<100 mA
1.8 A
Power consumption
PN(UN, IOUT = IN, ICHARGE = 0)
PMAX (UN, IOUT = ISTAT.BOOST, ICHARGE = max)
PCHARGE (UN, IOUT = 0, ICHARGE = max)
98 W
117.5 W
43 W
Internal input fuse Yes (15 A)
Switch-on time <5 sec
Switch-on time battery start (BS) n.a.
D Technical Data
D1 General Technical Data

UPSI-2406DPx
Revision 1-5 12
OUTPUT DATA – UPSI-2406DP1 / UPSI-2406DP2 / UPSI-2406DP3 (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
4 A
4.1 A
n.a.
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)
94 W
96.5 W
n.a.
Short-circuit proof Yes
No-load proof Yes
Overcurrent shutdown 4.2…4.5A for max. 3s; 4.6…10.8A for max. 100 ms
>10.8A for max. 5 ms
OUTPUT DATA – UPSI-2406DP1 / UPSI-2406DP2 / UPSI-2406DP3 (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
4 A
4.1 A
n.a.
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)
94 W
96.5 W
n.a.
Short-circuit proof Yes
No-load proof Yes
Overcurrent shutdown 4.2…4.5A for max. 3s; 4.6…10.8A for max. 100 ms
>10.8A for max. 5 ms
Switching time normal mode > battery mode <600µs

UPSI-2406DPx
Revision 1-5 13
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
ENERGY STORAGE UPSI-2406DP1
Charging method CC / CV / CP
Nominal voltage UN14.8 V
End-of-charge voltage 15.9 V
Charging current 1 C max.
Undervoltage protection 10.8 V
Battery technology Lithium-Ion
Nominal capacity 2.5 Ah (37 Wh)
Charging time (I_charge_max) 80 min
Buffer time (IN) 15 min
ENERGY STORAGE UPSI-2406DP2
Charging method CC / CV / CP
Nominal voltage UN8.3 V
End-of-charge voltage 8.3 V
Charging current 16 A max.
Undervoltage protection 4.5 V
Battery technology EDLC (Supercap)
Nominal capacity 5.73 kJ (3.88 kJ useful) / 1.59 Wh (1.08 Wh useful)
Charging time (I_charge_max) 2 min
Buffer time (IN) 30 sec

UPSI-2406DPx
Revision 1-5 14
ENERGY STORAGE UPSI-2406DP3
Charging method CC / CV / CP
Nominal voltage UN12.8 V
End-of-charge voltage 13.8 V
Charging current ≤2C (4.5…5 A)
Undervoltage protection 8.8 V
Battery technology LiFePO4
Nominal capacity 2.5 Ah / 33 Wh
Charging time (I_charge_max) 38 min
Buffer time (IN) 17 min

UPSI-2406DPx
Revision 1-5 15
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-2406DPx
Revision 1-5 16
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 DP1 /DP2: 0.6 kg, DP3: 0.8 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 63 mm / 120 mm / 100 mm ±0.5 mm
(without front connectors and DIN-Rail mounting bracket)

UPSI-2406DPx
Revision 1-5 17
ENVIRONMENTAL CONDITIONS
Ambient temperature (operation) DP1: 0…+50°C / DP2: -20… +65°C / DP3: -20… +55°C
Ambient temperature (start up without load) DP2: -30°C / DP3: -20°C
Ambient temperature
(storage / transport)
DP1: -20…+50°C / DP2: -30…+65°C / DP3: -30…+55°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 (valid only for UPSI-2406DP1 and UPSI-2406DP2)
UL ETL, UL61010-1
ETL, UL61010-2-201
CSA CSA C22.2 61010-1-12
CSA C22.2 61010-2-201
CB Scheme IEC 61010-1
IEC 61010-2-201

UPSI-2406DPx
Revision 1-5 18
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
±1kV
±2kV
Criterion A
Power frequency magnetic field immunity
EN 61000-4-8
Test level
Comment
30A/m
Criterion A

UPSI-2406DPx
Revision 1-5 19
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-2406DPx
Revision 1-5 20
D2 Drawing
63mm
120mm
9mm
100mm
44mm
Tolerance ±0.5 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]