RHINO PSB24-BCM960S User manual

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FOR TECHNICAL ASSISTANCE CALL
RHINO PSB24-BCM960S Battery Control Module
IMPORTANT SAFETY INSTRUCTIONS
• Retain these instructions. This manual contains important safety
instructions.
• When replacing batteries, only use the same type of batteries as
described in the Specifications.
• Proper disposal of batteries is required. Refer to the relevant local codes
for disposal requirements.
• Switch main power off before connecting or disconnecting the device.
Risk of explosion!
• If the orange status LED is on steady, this indicates a failure in the
installation. In this case, do not turn on power supply while the battery
is connected. Danger of explosion!
• To guarantee sufficient convection cooling, keep a distance of 50mm
above and below the device as well as a lateral distance of 20mm (for
vertical mounting) or 50mm (for horizontal mounting) to other units. See
Figure 4.
• Please note that the enclosure of the device can become very hot
depending on the ambient temperature and load of the power supply.
Risk of burns!
• The mains power must be turned off before connecting or
disconnecting wires to the terminals!
• Do not introduce any objects into the unit!
• Dangerous voltage present for at least 5 minutes after disconnecting all
sources of power.
• This is a built-in unit and must be installed in a cabinet or room
(condensation free environment and indoor location) that is relatively
free of conductive contaminants.
• CAUTION: FOR USE IN A CONTROLLED ENVIRONMENT.
READ INSTRUCTIONS BEFORE INSTALLING OR OPERATING
THIS DEVICE. KEEP FOR FUTURE REFERENCE.
3PET
E198298
249074
Highlights & Features
• Full corrosion resistant Aluminium chassis
• Suitable for 24V system up to 40A
• Built-in diagnostic monitoring for DC OK, Discharge and Battery Fail by
relay contacts
• LED indicator for DC OK, Battery Fail, DC Input, Battery Reverse Polarity
and Battery Discharge
• High MTBF > 500,000 hrs as per Telcordia SR-332
• Wide operation temperature range from -20°C to +60°C
• Conformal coating on PCBA to protect against chemical and dust
pollutants
General Description
The PSB24-BCM960S battery control module is designed to
support a 24V system with up to 40A output and 4.5 minutes
back up time for 15AH battery capacity. It offers a wide input
voltage from 24-28V and a wide operating temperature range
from -20°C to +60°C. This product comes with dry contacts for
battery management signals and LED indicator for battery status.
The rugged compact aluminum case is shock and vibration resis-
tant according to IEC 60068-2.
Risk of electrical shock, fire, personal
injury or death.
1. Turn power off before working on the device.
2. Make sure the wiring is correct by following all local
and national codes.
3. Do not modify or repair the unit.
4. Use caution to prevent any foreign objects from
entering into the housing.
5. Do not use in wet locations.
6. Do not use the unit in area where moisture or
condensation can be expected.
Device description (Fig. 1)
Figure 1
(2)
(1)
(3)
(4)
(1) Input & Output/Battery terminal block connector
(2) Signal terminal block connector
(3) LED display status
(4) Universal mounting rail system
RHINO Battery Control Module PSH-BCM360S Operating Instructions –1st Edition, Rev. A 11/2018
Power Supplies
tPWR-97

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RHINO PSB24-BCM960S Battery Control Module
Figure 5 1 2
Input & Output/Battery: 10mm [0.39in]
Signal: 7mm [0.28in]
In accordance with EN60950 / UL60950, flexible cables require
ferrules.
Use appropriate copper cables that are designed to sustain oper-
ating temperature of at least 60°C/75°C for USA or at least 90°C
for Canada.
Mounting
The unit can be mounted on 35mm DIN Rails in accordance with
EN60715. For vertical mounting, the device should be installed with
Input & Output/Battery terminal block on the bottom. For horizontal
mounting, the device should be installed with Input & Output/Battery
terminal block on the left side.
Each device is delivered ready to install.
Figure 2
12
3
Snap on the DIN Rail as shown in Fig. 2:
1.Tilt the unit slightly upwards and put it onto the DIN Rail.
2.Push downwards until stopped.
3.Press against the bottom front side for locking.
4.Shake the unit slightly to ensure that it is secured.
Dismounting
Figure 3 1
23
To uninstall, use a flat screwdriver to pull or slide down the latch as
shown in Fig. 3. Then, slide the PSU in the opposite direction, release
the latch and pull out the PSU from the rail.
Connection
The terminal block connectors allow easy and fast wiring. The
terminal block is IP20 compliant and thus provides the user safety
and protection from electrical shock hazards.
You can use flexible (stranded wire) or solid cables as follows:
Electrical Connections and Wire Size
Stranded / Solid Torque Remarks
mm² AWG N·m lb·in
Battery 3.3-13.3 12-6 1.52 13.5 Load: 0-20A
DC In/Out 8.4-13.3 8-6 1.52 13.5 Load: 20-40A
Signal 0.2-3.3 24-12 0.61 5.4 -
Wires between the battery control module and battery must not
be longer than 2m [6.5 ft]. For reliable and shockproof connec-
tions, the wire stripping length should be 10mm for Input & Output/
Battery terminal block connector and 7mm for Signal terminal block
connector (see Fig. 5 (1)). Please ensure that wires are fully inserted
into the connecting terminals as shown in Fig. 5 (2).
Orientation
20mm
50mm 50mm
Convection
Vertical Mounting Horizontal Mounting
Figure 4 Convection
50mm
Input/Output
terminal block
at bottom
Input/Output
terminal block
at left
RHINO Battery Control Module PSH-BCM360S Operating Instructions –1st Edition, Rev. A 11/2018
Power Supplies
tPWR-98

.
RHINO Battery Control Module PSH-BCM360S Operating Instructions –1st Edition, Rev. A 11/2018
RHINO PSB24-BCM960S Battery Control Module
Buffering Time
2.5 5 10 20 30 40
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
Buffering Time (s)
Output Current (A)
Buffe ring Time
Figure 8
7.5 AH 12AH 15AH
Power Derating
Figure 7
*Note: When used with power supply of different ratings, must follow power supply derating curve
(or this derating curve, whichever is lower).
0
10
20
30
40
50
60
70
80
90
-20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Percentage of Max Load (%)
Surrounding Air Temperature (°C)
32 41 50 68 77 86 95 104 113 122 131 140 149 158
Surrounding Air Temperature (°F)
-4 5 14 23
Power Derating Curve (Discharge Current)
0
10
20
30
40
50
60
70
80
90
100
110
-20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65
Percentage of Max Load (%)
Surrounding Air Temperature (°C)
32 41 50 68 77 86 95 104 113 122 131 140 149 158-4 5 14 23
Signal wiring diagram
Contact current: Imax = 1A
Contact voltage: Vmax = 24VDC/VAC (Secondary circuit)
No polarity requirement.
DC
+‒
DC OK
1
2Voc
Isc
‒+
BCM Device
Discharging
3
4Voc
Isc
BAT Fail
5
6Voc
Isc
Battery
Figure 6
Signal wiring diagram
Status Indicators
BCM Status Relay Output Connector LED Display
Status
Discharging BAT Fail DC OK
Battery Fully Charged Open Open Closed Green LED On
Battery Charging Open Open Closed Green LED Flashing
Battery Discharging*
(Buffering Mode) Closed* Open Closed Orange LED Flashing
No Battery Connected Open Closed Open Red LED On
Output Shutdown Open Open Open No Light
* With output current 3A to 40A.
Buffering Time
Output Current 7.5 AH 12AH 15AH
2.5 A 6,500s 14,500s 19,000s
5A 3,000s 7,000s 9,000s
10A 1,200s 2,400s 3,200s
20A 400s 1,100s 1,500s
30A 120s 450s 600s
40A 25s 200s 280s
Typical application notes
Figure 9
Typical Application Notes
9.1 Provide backup power during AC source interruption or failure
9.2 Can be combined with redundancy module (PSB60-REM40S)
BCM
+ ‒‒+
BAT DC
Power Supply
+ ‒
PE N L
Battery
24V
Load
‒+
PE
‒+
AC Input
BCM
+ ‒‒+
BAT DC
Redundancy
Module
+ ‒
+
OKOut
Power Supply
PE N L
Battery
24V
‒+
Power Supply
+ ‒
PE N L
Load
‒+
PE
+ ‒
ComVin
AC Input
Power Supplies
tPWR-99

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RHINO PSB24-BCM960S Battery Control Module
RHINO Battery Control Module PSH-BCM360S Operating Instructions –1st Edition, Rev. A 11/2018
Technical Specifications
Input (DC)
Nominal input voltage 24VDC
Voltage range 24-28 VDC
Maximum input voltage 30 ± 0.5 VDC
Input current Charging Mode: 2.0 ± 1.0 A (25°C), Discharging Mode: 40A Max.
Maximum inrush current (cold start) < 45A (25°C)
Charging time < 3 hr ± 1 hr (25°C)
Efficiency Charging Mode: > 70.0%, Discharging Mode: > 99.0%
Output (DC)
Nominal output voltage 24VDC typ. (depends on Vin)
Discharging voltage 23-28 VDC
Maximum output voltage 30 ± 0.5 VDC
Output current 40A Max.
Derating Refer to Fig. 7
Component derating Vin = 28.0 VDC, Max. load
Short circuit / Overload No damage
Batteries
Recommended battery types 24V VRLA or 2 x 12V VRLA
Recommended battery capacity 7.2-15.0 Ah
Battery voltage range
23-28VDC (continuous operating),
30VDC Max (maximum voltage that will not cause damage to the unit)
14VDC Min (voltage level of battery to enable “BAT Fail” function)
Battery fuse Auto 50A / 80V, FK3 (Littelfuse) or similar in the battery path (protects the wires between the battery and the battery control module)
General Data
Type of housing Aluminum
LED signals
Green LED On = Unit is fully charged
Green LED Flashing = Unit is charging
Orange LED Flashing = Unit is discharging
Red LED On = Battery fail (no battery is connected)
Orange LED On = Battery 24 V or DC 24 V reverse polarity
Signal relay contacts
DC OK = Contact is closed when battery is fully charged and the unit is ready to discharge/buffer.
DISCHARGING = Contact is closed when the unit is discharging/buffering with output current of 3-40 A.
BATTERY FAIL = Contact is closed when the battery fails to function.
MTBF > 500,000 hrs. as per Telcordia
Dimensions (L x W x H) 121mm x 50mm x 117.3 mm [4.76 fin x 1.97 fin x 4.62 fin] (See for compflete engfineerfing drawfings.)
Weight 0.39 kg [14 oz]
Connection method Screw connection
Stripping length Input & Output/Battery terminal block connector: 10mm [0.39 in]
Signal terminal block connector: 7mm [0.28 in]
Operating temperature (surrounding air temperature) -20°C to +60°C [-4°F to +140°F] (Refer to Fig. 7)
Storage temperature -25°C to +85°C [-13°F to +185°F]
Humidity at +25°C, no condensation < 95% RH
Vibration (non-operating) 10Hz to 500Hz @ 30m/S² (3G peak); displacement of 0.35mm; 60 min per axis for all X, Y, Z direction. Refer to IEC60068-2-6.
Note: all figures quoted are amplitudes (peak values)
Shock (in all directions) 30G (300m/S²) in all directions according to IEC60068-2-27
Pollution degree 2
Altitude (operating) 3000m
Certification and Standards
Electrical equipment of machines IEC60204-1
Electronic equipment for use in electrical power installations EN50178 / IEC62103
Safety entry low voltage PELV (EN60204), SELV (EN60950)
Electrical safety (of information technology equipment) UL/C-UL recognized to UL60950-1 and CSA C22.2 No. 60950-1 (File No. E198298), CB scheme to IEC60950-1
Industrial control equipment UL/C-UL listed to UL508 and CSA C22.2 No.107.1-01, CSA to CSA C22.2 No.107.1-01 (File No. 249074)
Protection against electric shock DIN57100-410
CE In conformance with EMC directive 2014/30/EU and Low Voltage Directive 2014/35/EU
Component power supply for general use EN61204-3
Immunity EN55024, EN61000-6-2 (EN61000-4-2, 3, 4, 5, 6, 8)
Emission EN55032, EN55011
3PET
E198298
249074
RoHS Compliant Yes
Safety and Protection
Isolation voltage:
Input & Output / PE
Signal / PE
Input & Output / Signal
1kVAC
1kVAC
1kVAC
Polarity protection Yes
Protection degree IP20
Safety class Class III
Power Supplies
tPWR-100

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Block Diagram
121.0
4.76
35.3
1.39
110.0
4.33
60.4
2.38
50.0
1.97
117.1
4.61
Dimensions
mm [inches]
RHINO PSB24-BCM960S Battery Control Module
RHINO Battery Control Module PSH-BCM360S Operating Instructions –1st Edition, Rev. A 11/2018
Power Supplies
tPWR-101

.
RHINO Battery Control Modules Overview
Battery Control Module Selection Guide
Part Number PSH-BCM360S PSB24-BCM960S PSL-24-BCM240 PSM24-BCM360S
Price
Highlights Most versatile
Highest power
Lowest cost/watt
Conformal coating
Lowest cost Legacy
Nominal Output
Voltage 24/48 VDC 24 VDC 24 VDC 24 VDC
Amperage Rating 15A at 24 VDC,
7.5 A at 48 VDC 40A 10A 15A
Number of Power
Inputs
Redundant inputs for two
independent power supplies One power supply One power supply One power supply
Battery Type 12V sealed lead acid 24V sealed lead acid 24V sealed lead acid 24V sealed lead acid
Protection Type
Over voltage,
Over current,
Deep discharge,
Reverse polarity,
Battery overcharge,
Over temperature
Battery Temperature
Compensation Yes No No Yes
Compatibility Universal Universal Universal Requires RHINO PSM24 power
supply
A battery control module (BCM), in combination with an
external sealed lead acid battery, can be added to a DC power
supply to create a DC uninterruptible power supply (UPS) that
will maintain power to a connected load upon loss of mains
power.
The battery control module performs several key functions in
the DC UPS system. Under normal conditions, it monitors the
status of the DC input power, monitors and controls charging
of the external lead acid battery, and provides status/alarm
contacts to allow remote monitoring of the state of the UPS.
In the event that the DC power supply voltage drops out, the
BCM monitors and supplies power to the load from the battery
and monitors the battery during discharge.
Several battery control modules, with a range of features, are
available for use with RHINO power supplies. Key differentiating
features of the battery control modules are delineated in the
following table.
Power Supplies
tPWR-91