Premium EPS-120-5192 User manual

OPERATIONS MANUAL
MANUAL DE OPERACIÓN
EPS-120-5192 & EPS-200-5193
Specifications are subject to change without notice. These products are not intended for use as critical components in life support or nuclear systems.
Las especificaciones están sujetas a cambios sin previo aviso. Estos productos no están diseñados para usarse como componentes críticos en sistemas de
soporte vital o nucleares.

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1. WARNINGS: ..................................................................................................................................... 5
2. INSPECTION OF THE DEVICE BEFORE RECEPTION:................................................6
2.1 LIST OF COMPONENTS ................................................................................................ 6
3. DESCRIPTION OF THE EPS-120-5192 AND EPS-200-5193 SYSTEMS...........7
4. CHARGER OPERATION ..............................................................................................................9
5. CHARACTERISTICS:..................................................................................................................10
5.1 ELECTRICAL, ENVIRONMENTAL AND MECHANICAL CHARACTERISTICS: ..........................10
5.2 ELECTRICAL BEHAVIOUR: ............................................................................................................11
5.3 PROTECTIONS................................................................................................................................. 11
5.4 SIGNALLING ....................................................................................................................................12
5.5 ALARMS ............................................................................................................................................12
5.6 CONNECTIONS AND SIGNALS: ...................................................................................................14
5.6.1 TERMINAL BLOCKS AND SIGNALS:.....................................................................................................................................14
5.6.2 PUSH BUTTON:............................................................................................................................................................................16
5.7 TEMPERATURE SENSOR................................................................................................................ 17
5.8 CONFIGURATION: ..........................................................................................................................17
5.9 COMMUNICATIONS: ...................................................................................................................... 17
6. INSTALLATION: ..........................................................................................................................18
6.1 CONDITIONS FOR INSTALLATION ..............................................................................................19
6.2 BATTERY INSTALLATION .............................................................................................................. 19
7. CONNECTIONS.............................................................................................................................20
7.1 CONNECTION OF THE MAINS POWER:....................................................................................... 21
7.2 GROUND, OUTPUT AND BATTERY CONNECTION:.................................................................... 21
7.3 CONNECTION OF THE BATTERY TEMPERATURE SENSOR:..................................................... 22
7.4 CONNECTION OF THE ALARM RELAYS:...................................................................................... 23
7.5 CONNECTING THE ETHERNET NETWORK CABLING:...............................................................23
8. COMMISSIONING....................................................................................................................... 24

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9. OPERATION...................................................................................................................................25
10. PROCESSES:............................................................................................................................. 26
10.1 ALARMS: ..........................................................................................................................................26
10.2 BATTERY CONSUMPTION: ............................................................................................................26
10.2.1 CHARGING MODE:................................................................................................................................................................. 26
10.2.2 DEVICE FULLY SWITCHED OFF:........................................................................................................................................ 28
10.2.3 DEVICE SWITCHED ON, WITH NO MAINS INPUT:..................................................................................................... 28
10.3 CONFIGURATION:..........................................................................................................................28
10.4 POWER-UP:...................................................................................................................................... 28
10.5 VARYING THE FLOATING VOLTAGE WITH THE TEMPERATURE: ...........................................29
10.6 BATTERY CONNECTION AND CHARGING: .................................................................................29
10.7 BATTERY DISCHARGE AND DISCONNECTION: ........................................................................30
10.8 RECOVERING BATTERY: ...............................................................................................................30
10.9 BATTERY TEST:............................................................................................................................... 32
10.10 CHANGING THE BATTERY: ..................................................................................................... 32
11. MAINTENANCE: BATTERY REPLACEMENT:.............................................................33
11.1 CHARGER ......................................................................................................................................... 33
11.2 BATTERIES....................................................................................................................................... 33
12. DIAGNOSTICS.........................................................................................................................34
13. REGULATIONS ........................................................................................................................35
14. LABELLING:.............................................................................................................................. 36
15. TRANSPORT, RECEPTION AND STORAGE INSTRUCTIONS...........................37
15.1 TRANSPORT..................................................................................................................................... 37
15.1.1 PACKAGING: ............................................................................................................................................................................ 37
15.1.2 HANDLING:...............................................................................................................................................................................38
15.1.3 TRANSPORT:............................................................................................................................................................................ 38

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15.2 RECEPTION:........................................................................................ 38
15.3 STORAGE:........................................................................................................................................ 39
16. ENVIRONMENTAL INFORMATION: ............................................................................. 40
17. WARRANTY............................................................................................................................... 41
18. ANNEXES:.................................................................................................................................. 42
18.1 ANNEX A: PERFORMANCE CURVES FOR EPS-120-5192:................................................................... 42
18.2 ANNEX B. PERFORMANCE CURVES FOR EPS-200-5193: ...................................................................43

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1. WARNINGS:
In order to prevent accidents and injuries, the following safety instructions must be observed when using
our equipment.
For your own safety, you must have read and understood the relevant safety instructions before working with
the device.
Keep the safety instructions in a place that is accessible to anyone who works with the equipment, so that
they can refer to them.
Our equipment may only be used by personnel who are trained and authorized.
Error messages. These must be observed under all circumstances, and the cause must be located and
eliminated.
Warnings about hazards. When using the device or accessing its interior, any parts that are live represent
a potential hazard.
Voltage in general. The device operates with a maximum voltage of 230 VAC. This voltage is dangerous and
may cause injury to anyone who comes into contact with conductive parts of the device.
In particular, live parts inside the equipment are regarded as hazardous areas. This may refer to the following:
several soldering points, printed conductors, terminals for mains connection, relay contacts, etc. Before
opening the device, disconnect all poles from the mains voltage.
External voltages. When disconnecting a device, it is also necessary to consider possible external voltages,
and the return of the powered device.
Fuses. Only original fuses must be used, depending on the equipment.
Use in accordance with the intended purpose. The device may only be used for its intended purpose. Any
use that is not in accordance with this purpose is prohibited. PREMIUM S.A. cannot be held liable for damages
resulting from use that is not in accordance with the intended purpose. In this case, the user must assume
sole responsibility for the risk. Uses that are in accordance with this purpose are defined in the documentation.
The device may only be exposed to permissible environmental influences. These influences are specified in
the technical data for the device.
Prohibition of arbitrary modifications. The device must not be modified, in terms of its construction or
safety technology, without our express consent. We cannot accept liability for damage caused by any
modifications that are made. In particular, any repair work, soldering on printed circuit boards or replacement
of components, modules or printed circuit boards is forbidden without the express authorization of
PREMIUM S.A. If using spare parts, only original PREMIUM S.A. parts must be used. PREMIUM S.A. declines
all liability resulting from inappropriate, negligent or incorrect installation of the device, or from incorrectly
connecting the device.
As a result of the continuous improvement policy, the contents of this manual may change without notice.

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2. INSPECTION OF THE DEVICE BEFORE RECEPTION:
Once the device has been received, a visual inspection of the assembly should be carried out in order to detect
any defects that are due to transport. It is then necessary to check that all the components listed in 2.1 have
been correctly supplied.
2.1 list of components
The product consists of the following parts:
•EPS-120-5192 or EPS-200-5193 charger.
•2-pole female connector for mains input
•6-pole female connector for output and battery
•5-pole female connector for alarms
•Temperature sensor with cables and connector
Note: Verification and warranty certificates: These will be stored electronically with the manufacturer and will
only be sent upon request.

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3. DESCRIPTION OF THE EPS-120-5192 AND EPS-200-5193 SYSTEMS
The EPS-120-5192 and EPS-200-5193 are 48V rectifiers-battery chargers that are able to manage the charging
of lead batteries, with capacities ranging from 1Ah to 15Ah and 10Ah to 20Ah respectively.
The total power that the EPS-120-5192 can deliver is 120W on a continuous basis, and 180W for 10 seconds
every minute. The input voltage is 230VAC.
The total power that the EPS-200-5193 can deliver is 200W on a continuous basis, and 400W for 10 seconds
every minute. The input voltage is 230VAC.
Figure 1. View EPS-120-5192 and EPS-200-5193 modules
The charger-rectifier architecture that is used has the battery connected directly to the output, as can be seen
in the following figure:
Figure 2. Diagram of blocks.
This equipment’s function is that of an uninterruptible power supply system, and its mission is to maintain
power to the loads at all times. To do so, it must:
-Provide an uninterruptible power supply at its output that is within the specified range.
-Protect itself in normal operating situations (power-up, intermittent overloads, etc.), as well as
abnormal ones (short circuits and continuous overloads at its output, etc.).
-Carry out appropriate treatment of the batteries required for its operation:
-Try to maximize the life of the batteries and minimize their charging time.
-Implement protections against inappropriate operations that could damage them (deep
discharge and adjustment of floating voltage with temperature).
Phas
+48Vcc
Neutral
Groun
0V
AC / DC
Control V-I
10kV isolation
BATTERY

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The battery is charged using the UI method, i.e. at a constant voltage and with a limited current. When the
battery is fully charged, these chargers keep the battery floating, supplying the
small maintenance current that is required by the battery. When the battery has totally or partially discharged
after a mains failure, the chargers modify the battery/output voltage to replenish the discharged energy in
the shortest possible time. To do so, they increase the battery/output voltage, but they are careful to limit the
maximum value of the charging current received by the battery. Both the battery/output voltage under load
and the maximum charging current are values that parameters can be set for.
Unlike other equipment, this equipment incorporates a battery status check system which measures the useful
capacity of the battery.
At the same time, it incorporates a high precision temperature sensor that allows for the optimal battery
charge, based on its temperature.
On the other hand, the device has four alarm signals that use potential-free contacts (mains failure, urgent
failure, non-urgent failure and end of autonomy). On the front, there are 8 LED indicators: 3 green "Device
ON", "Charging mode" and "Battery test in progress” indicators; one yellow "Battery discharging” indicator;
and 4 red "Mains fault", "Output failure", "Battery failure" and "Equipment failure".
The following figure shows the block diagram for this equipment:
Figure 3. EPS-120-5192 and EPS-200-5193 Block Diagram
Phas
+48Vc
Signalling
Local
Neutra
Grou
Alarms
0V
Control
AC / DC
Control V-I
10kV isolation
Ethernet

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4. CHARGER OPERATION
This equipment, which is supplied with an input voltage of 230VAC (range of 184-265Vac), acts as an
AC/DC switched converter, with galvanic isolation between input and output (up to 10kV at industrial frequency
and 20kV lightning impulse).
The power stage transforms the energy from the mains into a stabilized DC voltage, providing isolation
between input and output.
The device control is responsible for maintaining regulation of the output voltages, charging the battery,
and monitoring other parameters to ensure that they are within the set margins. It is also responsible for
signalling, alarms and Ethernet communications.
In the event of a mains AC power failure, the control is still powered by the batteries. When it reaches a
limit discharge value, a contact that is in series with the battery is opened. This prevents it from being damaged
by a deep discharge. Once this contact is opened, the charger will be disconnected and will remain so until the
AC mains voltage returns or a reconnection is forced from the battery using the button provided for this
purpose.
Figure 4. EPS-120-5192 and EPS-200-5193 chargers
This equipment has a battery status control system (Battery test). The state of the batteries is monitored on
a regular basis. In addition, this measurement is always carried out when the batteries are floating.
This test consists of discharging the battery through the loads that are connected to the output of the device.
The objective is to verify that the batteries still have the minimum energy storage capacity required for the
application.
The battery is charged using the UI method, i.e. at a constant voltage (or quick charge) and with a limited
current. When the battery is fully charged, these chargers keep the battery floating, supplying a small
maintenance current. When the battery has totally or partially discharged after a mains failure, the chargers
modify the output voltage, so that the current received by the battery is limited to a charging current that
parameters can be set for.

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5. CHARACTERISTICS:
5.1 ELECTRICAL, ENVIRONMENTAL AND MECHANICAL CHARACTERISTICS:
CHARACTERISTICS OF THE AC INPUT
EPS-120-5192
EPS-200-5193
Mains input voltage
230Vac
Mains voltage range
-20%...+15%
Mains frequency range
47...63Hz
Starting current
< 12A
< 20A
CHARACTERISTICS OF THE DC OUTPUT
Rated output voltage
48 V
Battery voltage
48 V
Voltage range:
No mains or limiting the charging current 39…60V
Line regulation:
Variation of the output for the input voltage range. <0.1%
Maximum continuous current:
Output 48V+battery charge (Vout=39V) 3.08A 5.2A
Total output power:
120W
200W
Total peak output power (200ms):
Without help from the battery.
240W
500W
Total peak output power (10s):
Without help from the battery.
180W
400W
Total peak output power (60s):
180W
The charger delivering
120W and the battery
delivering the rest.
400W
The charger delivering
200W and the battery
delivering the rest.
Ripple
50mVpp
Noise (BW 20MHz)
100mVpp
Performance:
At rated input voltage and rated power
>84%
(See annex with efficiency curve)
CHARGER CHARACTERISTICS
Type of battery
Watertight lead
Rated battery voltage
48V
Battery capacity
1Ah-15Ah
10Ah-20Ah
Maximum battery charging current (for which
parameters can be set)
3,077A
5.2A
Battery self-consumption in standby
< 150µA
Battery self-consumption without AC:
<5% Rated power
<3% Rated power
Minimum battery voltage:
To begin battery recovery process.
4V
Accuracy of temperature sensor
1ºC
Accuracy of temperature measurement:
Across the entire measurement channel
3ºC
ENVIRONMENTAL CHARACTERISTICS
Operating temperature
-25…60°C
Storage temperature
-40…85°C
Relative humidity
5…90% without condensation
Cooling
Natural convection
Altitude
<1000m
Environmental requirements
RoHS, according to the 2002/95/CE Directive
MECHANICAL CHARACTERISTICS
Dimensions:
Including the connectors.
247x115x115mm (Width x Height x Depth)
Weight:
<1.25kg
<1.4kg
Degree of protection
IP20

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Figure 5. EPS-120-5192 and EPS-200-5193 dimensions and connections
5.2 ELECTRICAL BEHAVIOUR:
The following units have been defined in order to specify the dielectric strength:
UNIT
SIGNAL
G1
AC input
G2
Alarms
G3
Temperature sensor + 48V output + Battery + NC
G4
Ethernet Port
G5
Ground
The dielectric strength between units is as follows:
Testing poles
Lightning
impulse
1.2/50µs
Dielectric strength
50Hz 1 minute
Isolation with
impulse
Pole-1 Pole-2
G1
G2 + G3 + G4 + G5
± 20 kV
10 kVac
± 5 kV
G2
G1 + G3 + G4 + G5
± 2 kV
1 kVac
± 2 kV
G3
G1 + G5
(G2 + G4 together without connecting
to G5)
± 5 kV 2 kVac ± 5 kV
G4
G1 + G2 + G3 + G5
± 2 kV
1 kVac
± 2 kV
5.3 PROTECTIONS
The mains input is protected by a fuse that is dimensioned for extreme cases in which the device could break
internally and require specialized technical servicing.
The device protections are as follows:
•Mains overvoltage protection with varistors.
•Secondary overvoltage protection.
•Output overload and short-circuit protection with current limiting.
The battery has different degrees of protection:
•Electronic charging current limitation.
•Short-circuit protection with a self-rearming fuse.
ETH
J1
J4
J3
J2

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•Protection against deep discharge of the battery using a relay that is in series with the battery,
guaranteeing that it will be disconnected when the voltage at the terminals reaches the preset minimum
value.
•Battery polarity inversion protection.
5.4 SIGNALLING
The module has eight LEDs on the front for local signalling:
LED Name
Colour
Mode
Indication
Device ON
Green
Steady light
Charger running
Charging mode Green
Steady light
Battery charging floating mode
Blinking
Battery charging in constant voltage mode
Battery test in progress Green Steady light Battery test in progress
Battery discharging
Yellow
Steady light
Battery discharging
Mains fault
Red
Blinking
Mains input voltage out of range
Output failure
Red
Blinking
Output voltage out of range
Battery failure Red Steady light Failed battery test, degraded batteries
Blinking
Battery voltage out of range
Equipment failure Red
Steady light
Battery temperature sensor error
Blinking
Internal charger error
When the charger enters IP LOCAL mode with the push button, all the LEDs blink at the same time.
5.5 ALARMS
There are four potential-free contact alarm outputs with the following characteristics:
•Maximum switchable voltage 60Vdc
•Maximum current: 100mA
Alarm Name
Status
Operating logic
Urgent failure NC
In normal charger operation, it is open.
It is kept closed when there is a battery failure, internal device failure or when the
internal temperature is outside the range.
End of autonomy NA Closes when the battery is discharging and the voltage drops to the set minimum value
Mains failure
NA
Closes if the AC mains voltage is outside the range
Non-urgent failure NA Closes when the output voltage is outside the range, when the battery temperature is
outside the range or when there is a temperature sensor error.

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Figure 6. EPS-120-5192 and EPS-200-5193 alarms detail
A more detailed description of the operation of the equipment can be found in section 3.2 of this operating
manual.

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5.6 CONNECTIONS AND SIGNALS:
5.6.1 TERMINAL BLOCKS AND SIGNALS:
The connections for the EPS-120-5192 and EPS-200-5193 chargers are as follows:
Connector
Pins
Signal
Characteristics
Minimum
cross-
section
Maximum
cross-
section
J1
Input
1
AC input, Phase L
230 Vac rms
0.75 mm22.5 mm2
2
AC Input, Neutral N
J2
DC Output
1
Ground (Functional)
THIS IS NOT A
PROTECTION
GROUND
0.75 mm22.5 mm2
2
Free
No connection
3
Battery terminal positive
4
Battery terminal negative
5
Output terminal negative
6
Output terminal positive
J3
Temperature
measurement
1
Battery temp. sensor negative
Sensor power supply
-
Prewired
2
Battery temp. sensor
measurement
Sensor
measurement
3
Battery temp. sensor positive
Sensor power supply
+
J4
Alarms
1
Urgent Failure Alarm
(URG)
NC Contact
0.75 mm21.5 mm2
2
End of autonomy (EOA)
NA Contact
3
Mains Failure Alarm
(FAC)
NA Contact
4
Non-Urgent Failure Alarm
(NUR)
NA Contact
5
Common Alarms (COM)
ETH
1-8
Ethernet Port
Figure 7. Detail of J1

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Figure 8. Detail of J2
Figure 9. Detail of J3 and J4
Figure 10. ETH detail

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5.6.2 PUSH BUTTON:
The EPS-120-5192 and EPS-200-5193 chargers have a button (BT1) indicated on the front panel as
"Battery Reconnection".
Figure 11. Position of the BT1 push button on the EPS-120-5192 and EPS-200-5193 chargers
The push button enables the following functions:
- Starting the charger without AC power: When the charger is completely shut down (without AC
input but with the batteries connected), if the button is pressed for 5 seconds, the device starts
using battery power, if the batteries have a voltage within the admissible range (a charger value
for which parameters can be set).
- When the device is running, at constant voltage (quick charge), floating, with the battery charged
or with no battery, if the button is pressed for 5 seconds, it disconnects the batteries and then
reconnects them to check that they are connected. The device will indicate that the button has
been pressed for 5 seconds when all the LEDs light up and remain steady. If, after performing this
check, it detects that the battery is present, the charging process continues and the battery test
failure alarm (if active) is cleared. If the battery is not detected, the urgent alarm for battery not
connected is activated.
- If it is pressed for more than 60 seconds, the device is reset to factory settings.
- Access to the device through the local IP: The charger can be accessed locally and remotely via
the ETH port. The device has 2 IP addresses, only one of which is active at any given time.
These IP addresses are:
oREMOTE IP: Parameters can be set for this, and it is different for each device. Default
value 200.0.0.1.
oLOCAL IP: 100.0.0.1; this is fixed for all devices.
Therefore, it is always possible to access the device in order to configure it by connecting
through the LOCAL IP, even if the REMOTE IP that is configured is unknown.
Ways to change the active IP:
- Switch to LOCAL IP: the device must be switched on and running. In addition, the button must
be held down for 10s.
When the charger is in this mode, all the LEDs blink at the same time.
BT1

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Figure 12. Push button and LEDs.
- Return to REMOTE IP. This can be done in several ways:
oPress the button again for 10 seconds.
oBy time. The charger automatically switches to REMOTE IP after 20 minutes in LOCAL IP
mode.
5.7 TEMPERATURE SENSOR
The EPS-120-5192 and EPS-200-5193 chargers incorporate a pre-wired temperature sensor to measure the
ambient temperature near the batteries, in order to optimise their life.
By compensating the output voltage with the temperature, these chargers maximize the life of the batteries
used.
The characteristics of the sensor are shown below:
CHARACTERISTICS
Dimensions
39 x 16 x 2 mm (Width x Height x Depth)
Operating temperature
-40 to 80 ºC
Storage temperature
-40 to 80 ºC
Wiring length
2 metres (maximum: 10m)
1
Note 1: It will be possible to supply the sensor pre-wired in other lengths upon request:
Standard 5m and 10m sizes available.
5.8 CONFIGURATION:
The charger parameters can be configured using an XML configuration file and/or a web browser. However,
the parameters can only be modified within the range established for each of them.
5.9 COMMUNICATIONS:
The EPS-120-5192 and EPS-200-5193 chargers have an Ethernet port for communications.
The charger has a Web interface that allows you to look up the output voltage, the power consumed at the
output, detailed alarms, the configuration of the device, the firmware loaded, the status of the batteries etc.
The device allows configurations to be loaded using an XML configuration file and/or by changing parameters,
using a generic web browser (for more details, see the device's communications operating manual).

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6. INSTALLATION:
The device can be wall mounted, and it has natural convection cooling. Its installation position is as shown in
the following figure. It is important not to cover the ventilation slots, so that air can circulate freely.
Figure 13. View of typical EPS-120-5192 and EPS-200-5193 mounting position
The weight of the chargers, including connectors, is less than 1.4kg.
For installation, it is recommended to use 4 M4 or M5 screws with standard flat washers, with a maximum
tightening torque of 1Nm.

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6.1 CONDITIONS FOR INSTALLATION
The device must be installed in a location that has all of the following characteristics:
•Liquids, dust and/or objects must be prevented from getting into the device through the ventilation
grilles, as the integrity of the device would then be at risk.
•It must be protected from atmospheric agents.
•The ambient temperature must be within the operating range of the device.
•To ensure isolation from the AC input ground for the device (including the 20kV lightning impulse), a
distance of at least 25mm must be guaranteed between it and any metal part that is connected to
ground.
•It will need to facilitate connections.
•Proximity to magnetic fields and high-power systems must be avoided.
•The working position will be as described above, and the location must be free from vibrations and
able to support the weight of the device.
•Exposing the system to corrosive gases or products must be avoided.
•It must not lead to the obstruction of the ventilation outlets (which ensures the correct dissipation of
the heat generated inside the device).
On the other hand, there are some recommendations that must be taken into account for the connection
boards of the device.
•It will be necessary to have safety protective equipment (specifically, a differential switch) on the
mains line, upstream of the device. This, in turn, will allow the mains to be disconnected during
installation and maintenance processes.
•This protective equipment must be slow-acting, so that it does not trip as a result of the device's
inrush current.
6.2 BATTERY INSTALLATION
The batteries must be installed in a location that is free from humidity and well-ventilated. If they are installed
in enclosed locations, it is important that adequate ventilation is maintained to minimize condensation and
ensure that gases generated during charging are evacuated.
A "No Smoking" warning must be posted in the location where the batteries are installed, as well as a sign
prohibiting any activity that may cause a spark in the battery room.
You will need to place the instructions for battery handling, safety and maintenance in the installation location.
In this way, the user will be able to consult the battery installation and maintenance characteristics in a more
efficient manner.
Insulated tools and appropriate clothing must be used. No rings, wristwatches or metal items should be worn
when handling or installing the batteries.

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7. CONNECTIONS
Electrical connections must be made in the terminals or connectors that are marked for this purpose. The
exact or compatible references specified for these items should also be used for each connection. The following
figure shows the general connections diagram.
Figure 15. General connections diagram.
The layout of the connectors can be seen in the following figure:
Figure 16a. Left side view
Figure 16b. Right side view
Phas
+48Vcc
Ethernet Local
Area Network
Neutral
Groun
Management unit
Potential
-free alarms
0V
Input
AC
EPS-120-5192
or
EPS
-200-5193
Ground
Battery+
Battery-
48V-
48V+
Temp.
Sensor
Alarm
relays
Ethernet