Trumpf TruConvert DC 1008 User manual

Operator's manual
TruConvert DC 1008 – 1010,
TruConvert System Control
TruConvert Modular

Operator's manual
TruConvert DC 1008 – 1010,
TruConvert System Control
TruConvert Modular
Original operator's manual
Edition 2022-06-01

Order Information Please specify when ordering this document:
Operator's manual
TruConvert DC 1008 – 1010, TruConvert System Control
Edition 2022-06-01
Document number A67-0140-00.BKen-001-07
Address for orders TRUMPF Hüttinger GmbH + Co. KG
Technische Redaktion
Bötzinger Straße 80
D-79111 Freiburg
Fon: [phone] - 0
Fax: [phone] - 1150
Internet: http://www.trumpf-huettinger.com
E-Mail: [email protected]
© TRUMPF Hüttinger GmbH + Co. KG

Good to know
Provide the serial number when you contact the Service depart-
ment. The serial number can be found on the name plate of the
device.
How to reach our Service department:
[phone]
[phone]
[email protected]
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Need help?
Telephone
Fax
E-mail

II Good to know 2022-06-01 A67-0140-00.BKen-0
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Table of contents
1 Safety 5
1.1 Important notes 5
1.2 Storing the operating instructions 5
1.3 Warning signs 5
1.4 Using the DC-DC module 6
1.5 Authorized personnel 7
1.6 Warning signs on the DC-DC module 8
1.7 What you must know as an operator 8
1.8 Dangers from high voltages 9
Protective measures taken by the manu-
facturer
10
1.9 What you must know as an operator 10
Ensuring safe operation of the DC-DC
module
10
Check periodically 10
2 Description 11
2.1 Fields of application 11
Typical fields of application 11
2.2 Function description 11
Operation 13
2.3 Construction 13
TruConvert DC series 1000 construction 13
TruConvert System Control construction 16
2.4 Display elements 17
3 Technical specifications 18
3.1 TruConvert DC Series 1000 data 18
3.2 TruConvert System Control data 24
3.3 Technical data dependent on device variant
(overview)
26
4 Interfaces 28
4.1 Protective earth 28
4.2 Supply voltage 24 V DC 29
4.3 DC link 30
4.4 Battery connection 30
4.5 RS-485 data input/data output (IN/OUT) 31
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4.6 Interfaces on the system control 32
24 V supply voltage (DC) 32
Ethernet 33
RS-485 33
5 Standards and directives 34
5.1 CE certification 34
5.2 EU declaration of conformity TruCon-
vert DC 1008 / TruConvert DC 1010
35
5.3 EU declaration of conformity TruConvert Sys-
tem Control
36
5.4 CSA certification 37
Location of the CSA mark 37
6 Installation 38
6.1 Inspecting the delivery 38
6.2 Disposing of packaging material 38
6.3 Transport 38
6.4 Storage conditions 38
6.5 Requirements for the site 39
6.6 Possible installation positions 40
6.7 Electrical connection 41
Establishing electrical connection 42
Using ferrite core to achieve the limit
value for level C1
44
Connection diagram with 3 DC-DC mod-
ules (example)
46
6.8 Dismantling the DC-DC module 46
6.9 Shipping the module 47
6.10 Disposing of the module 47
7 Operation 48
7.1 Commissioning 48
Performing initial commissioning 48
7.2 Active interface 53
7.3 Operation via web-based user interface 53
Calling up the web GUI 53
Orientation of the user interface 54
Menu structure 57
7.4 Operation via Modbus 58
Establishing a connection 58
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Addressing modules via Modbus 59
Modbus Register Map 60
7.5 Transmission of power 65
Switching the transmission of power on/off 65
7.6 Displaying and resetting messages 67
Displaying messages of the web GUI 67
Modbus: displaying and resetting mes-
sages
69
7.7 Overload 71
Operating with overload 71
Examples: Reduce and then again
increase overload capacity
73
7.8 DC voltage droop 73
Function description of DC voltage droop 73
Switching on DC voltage droop 75
Parameterization of DC voltage droop 76
7.9 Actual values 78
Display actual values 78
7.10 Process set values 79
Set process set values 79
7.11 Precharger 79
7.12 Data backup 80
Saving parameters and resetting to fac-
tory settings
80
7.13 System configuration 81
Setting the system configuration 81
7.14 System settings 83
Setting the system time 83
Changing network settings 83
7.15 Software update 85
Perform software update 85
7.16 Device information 85
Displaying device information 85
7.17 State diagram 87
8 Maintenance 88
8.1 Periodic check of the environmental condi-
tions
88
8.2 Cleaning 88
8.3 Exchanging fans 88
8.4 Performing software updates 88
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9 Troubleshooting 89
9.1 Fault indication and messages 89
Fault indication with the LEDs 89
9.2 Messages 89
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1. Safety
1.1 Important notes
■This is a product for commercial and industrial use in the
"second environment". This is the environment to which all
commercial, light manufacturing and industrial enterprises
belong, with the exception of those that are connected
directly to the low-voltage network for the supply of buildings
for residential use.
To prevent disturbances, restrictions regarding the installa-
tion or additional measures may be necessary.
■The products listed in the declaration of conformity are not
independently operating products in the sense of the EMC
directive. The EMC situation cannot be evaluated until the
product has been incorporated in a complete system. The
evaluation was verified for a typical system configuration, but
not for the individual product.
■All technical safety requirements in the product-specific docu-
mentation (operating instructions, manual, etc.) must be
adhered to throughout the entire product lifecycle.
1.2 Storing the operating instructions
IMPORTANT SAFETY INSTRUCTIONS
ØSAVE THESE INSTRUCTIONS.
These operating instructions contain safety notices that must be
observed during installation and maintenance. Therefore, keep
the operating instructions in a safe place for the entire life cycle
of the device.
Include the operating instructions if you sell the device or set it
up at another location.
1.3 Warning signs
Certain activities can cause danger during operation. Corre-
sponding warning signs concerning the dangers should precede
instructions concerning the activities. Danger signs are located
on the device.
A warning sign contains signal words which are explained in the
following table:
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CAUTION

Signal word Description
DANGER Indicates a major danger. If it is not avoided,
serious injuries or death will result.
WARNING Indicates a dangerous situation. If it is not
avoided, it may lead to serious injuries.
CAUTION Indicates a potentially dangerous situation. If it
is not avoided, injuries may occur.
NOTICE If such a situation is ignored, material damage
may result.
Description of the signal words Tab. 1
1.4 Using the DC-DC module
The DC-DC module is used as a link between a DC link and a
DC voltage load or DC voltage source.
The DC voltage source can consist of a battery.
The energy can flow in either direction.
■The DC link voltage must be balanced to earth.
■Used batteries: All common rechargeable battery systems.
− The DC-DC module may only be operated in combina-
tion with intrinsically safe batteries. The batteries must
be connected in accordance with the applicable local
standards. The relevant standards are DIN EN 50272-2,
IEC62485, IEC61427-1 depending on the type of battery.
− Maximum permissible voltage: 75 VDC.
Any use not listed under "Typical fields of application" contra-
venes the intended purpose. TRUMPF is not liable for any ensu-
ing damages, in particular for property damage, personal injury
and loss of production. The operator bears all risks. The war-
ranty is rendered null and void.
Impermissible uses include, for example:
■Use of incorrect components.
■Operation on voltages outside the specification.
■Operation on DC link voltages which are not balanced to
earth.
■Faulty installation (e.g., cables reversed).
■Use in unauthorized installation position.
■Misuse by untrained personnel.
■Input of wrong parameters.
■Use in unsuitable environmental conditions:
− Condensation, icing.
− Conductive soiling.
− Corrosive conditions (e.g. battery fumes, salt spray).
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Typical fields of application
Liability exclusion
Impermissible uses

− Voltages outside overvoltage category III (impulse with-
stand voltage of max. 4 kV).
− Operation at more than 2000 m above sea level.
− Operation outdoors.
− Failure to observe "pollution degree 2" environmental
condition.
− Operation in an explosive environment.
■Operation with non-intrinsically safe batteries.
1.5 Authorized personnel
Installation, operation, configuration and maintenance work may
only be performed by authorized, trained and instructed person-
nel.
Authorized persons must be trained and be familiar with the
standards and regulations relevant to their tasks.
It is the duty and responsibility of the operator to maintain the
qualifications of the authorized personnel. The authorized per-
sonnel must therefore be trained at regular intervals.
The following activities may only be performed by authorized per-
sons:
■Setting up the DC-DC module.
■Connecting the DC-DC module.
■Commissioning the DC-DC module.
■Dismantling the DC-DC module.
■Operating the DC-DC module.
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1.6 Warning signs on the DC-DC module
1 Read operating instructions 3 Dangerous residual voltage 5 Dangerous battery voltage
2 Dangerous voltage 4 Destruction of the device by
reverse polarity at the battery
connection
Warning signs on the DC-DC module Fig. 1
1.7 What you must know as an operator
Note
All warning signs must be present and legible.
If one or more of these warning signs is missing or not legible,
contact TRUMPF to request new warning signs.
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Warning sign Meaning
This sign indicates that the operat-
ing instructions must be read.
Sign warns of hazardous voltage.
Sign warns of hazardous residual
voltage.
Sign warns of destruction of the
device by reverse polarity at the
battery connection.
Sign warns of hazardous voltage
on the battery connections.
Meaning of the warning signs Tab. 2
1.8 Dangers from high voltages
Life threatening voltage!
The voltages present at the DC-DC module are life-
threatening.
ØOnly have work on the DC-DC module performed by author-
ized, trained and instructed personnel.
The DC-DC module produces voltages that can endanger
human life and health. These voltages occur both in the DC-DC
module as well as at the outputs of the DC-DC module.
The DC-DC module's connection cables carry voltages that are
life-threatening.
A person who comes into contact with live DC-DC module parts
may be killed or severely injured.
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WARNING

Simultaneous control via web-based user interface and
Modbus is possible!
Power transmission stopped using the user interface can
be started again and reversed via Modbus.
ØBefore carrying out work on the device, deenergize all sup-
ply lines and secure against reenergizing.
ØMake sure that the device is controlled via one channel
only (user interface or Modbus).
Protective measures taken by the
manufacturer
The DC-DC module is installed in an enclosed metal casing.
1.9 What you must know as an operator
Ensuring safe operation of the DC-DC
module
1. The DC-DC module must not be opened.
There are no parts within the DC-DC module that can be
serviced by the user.
2. Only operate the DC-DC module within the conditions descri-
bed in chapter "Technical specifications".
3. For the electrical connection, use only cables that are in per-
fect condition and have the correct dimensions.
Check periodically
ØPeriodically retest acc. to DGUV regulation 3 (DGUV = Deut-
sche Gesetzliche Unfallversicherung – German Statutory
Accident Insurance Association).
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WARNING

2. Description
2.1 Fields of application
Typical fields of application
The DC-DC module is used as a link between a DC link and a
DC voltage load or DC voltage source.
The DC voltage source can consist of a battery.
The energy can flow in either direction.
■The DC link voltage must be balanced to earth.
■Used batteries: All common rechargeable battery systems.
− The DC-DC module may only be operated in combina-
tion with intrinsically safe batteries. The batteries must
be connected in accordance with the applicable local
standards. The relevant standards are DIN EN 50272-2,
IEC62485, IEC61427-1 depending on the type of battery.
− Maximum permissible voltage: 75 VDC.
Destruction of the device.
If the voltage on the low-voltage side is higher than the
voltage on the high-voltage side, there is a risk of current
flowing in an uncontrolled manner.
ØMake sure that the voltage on the high-voltage side is at
least 50 VDC higher than the voltage on the low-voltage
side.
The TruConvert System Control external control must be used
to monitor and control the DC-DC module.
2.2 Function description
The DC-DC module is a bidirectional DC voltage converter for
charging a battery from a DC link (high voltage) and for feeding
energy from a battery back into the DC link (high voltage).
Voltage limits can be set both for the battery charging and dis-
charging processes as is appropriate for the batteries used.
Note
Instead of a battery, a different DC energy source or DC load
can also be used. For the sake of simplicity, we always speak
of batteries in these operating instructions.
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Typical fields of application
NOTICE
Control

The device is air-cooled.
■The DC-DC module draws energy from a DC link (high volt-
age) and charges a battery.
■The DC-DC module draws energy from a battery and feeds
it into a DC link (high voltage).
■The DC-DC module can be operated as a stand-alone
device.
■Up to 3 DC-DC modules can be connected in parallel on the
DC link side (more devices on request) (see "Fig. 2",
pg. 12).
■Up to 3 DC-DC modules can be connected in parallel on the
battery side (see "Fig. 3", pg. 12).
1 DC link 3 Battery
2 DC-DC module
Parallel operation of DC link side Fig. 2
1 DC link 3 Battery
2 DC-DC module
Parallel operation of battery side Fig. 3
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Operation modes
Configurations

Operation
The DC-DC module can be operated via:
■PC with a web browser
■Modbus TCP/UDP
In both cases, the TruConvert System Control must be con-
nected upstream. In the "DC only" configuration, a TruCon-
vert System Control can control up to 16 DC-DC modules (see
"Fig. 4", pg. 13).
1 PC with web browser or Mod-
bus master
3 TruConvert DC series 1000
2 TruConvert System Control
Operation with TruConvert System Control Fig. 4
2.3 Construction
TruConvert DC series 1000 construction
The DC-DC module is housed in an enclosed metal housing.
The fan on the inside of the front panel draws in air for cooling.
All connecting elements are located on the back side.
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Overview

1 Front panel with mounting
brackets
2 Display elements 3 Opening for air intake
Overview Fig. 5
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