User manual | DIN-UPS Manual_48-5V_110416.indd

DIN Rail UPS
Model: DIN-UPS 48-5
Installation/Operation Manual
Table of Contents
Section
Page
Section
Quick Start
2
1) General Information
4
A) Battery Type/Charge Curve
6
Materials Provided
4
4
B) Time Charge Current Limit/Battery
Charge Level
7
Optional Equipment
2) Safety Information
4
C) System Setttings
7
3) Installation/Wiring
4
4) Settings
5) Operation
A) Mounting
4
A) Status Indicator LED’s
B) Wiring
5
B) LVD
6
8
8
9
1. AC Input
5
6) Protection
2. Output
5
7) Specifications
9
C) Alarm Contacts, Form C
5
8) Troubleshooting
10
D) Temperature Compensation Sensor
6
9) Warranty
10
9
M-DINUPS485
AS OF 110416
1
P.O. Box 1306
Newport Beach
California 92663
Page
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
Quick Start Guide
Figure 1: Quick Start
E
B
F
1)
C
2)
D
3)
H
a
b
j1
j2
c
G
A
A) AC Input: Wire Input Block (lettered left to right)
a) AC Hot 230 VAC: no jumper installed across j1 & j2
AC Hot 115 VAC: wire jumper across j1 and j2
b) Neutral
c) Earth Ground
j1 & j2) Jumper these two inputs for 115 VAC operation
See page 5 for details.
B) Battery Output: one terminal each for plus and minus.
See page 5 for details.
C) Battery Charge Current Limit: Allows setting maximum
current flow to battery during recharge cycle, use when
low amp-hour batteries are applied to system to prevent
overheating when recovering dead batteries. Adjustment
range 20-100% of available charge current. (Available
charge current = unit output rating of 5 amps - load
demand. Note: the unit has a load priority circuit, all
Mounting DIN DC UPSto DIN Rail
A
produced power is made available to the load, remaining
power is available for battery charging). See page 6
for details.
D) Battery Temperature Sensor (optional): Plug in port
(RJ-45). See page 6 for details.
E) Output to Load: The unit has a load priority circuit, all
produced power is made available to the load, remaining
power is available for battery charging. See page 5 for
details.
F) Form C Contacts: Activate upon:
a. AC power fail
b. Low battery or poor battery condition
See page 5 for details.
Removing DIN DC UPS from DIN Rail
A
B
B
Twist
Twist
Insert flat head screwdriver in slot of bottom tab and twist to extend bracket
2
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
G) System Settings: via plug-in jumper programing
terminals located on bottom of the unit.
a. Install jumper per illustration below (Table 1) to:
i. Select float voltage per Battery Type and enable
Absorption Charge (see page page 7 for details)
ii. Enable Battery Test (Functional Setting)
See page 7 for details on functional settings.
H) Status Indicator LED’s
1. AC Fail: Operating on battery back-up power (LED
On). LED extinguishes when AC is present.
2. Low battery, or poor battery condition
3. Charger Output Status and Fault Mode Diagnosis: by
blink code:
Charge Status Blink Code:
• Bulk: 5 blink/second - Recovery
• Absorption: 2 blink/second - Bulk
• Float: 1 blink/second
Fault Mode Diagnosis Blink Code:
• Reverse Polarity: 1 blink, pause
• Battery Not Connected: 2 blink, pause
• Overload or Short Circuit: 4 blink, pause
• Bad Battery Wire Connection, or Bad Battery
(internal impedance): 5 blink, pause
• Bad Thermal Sensor: 7 blink, pause and diagnostic
See page 8 for details.
Table 1: System Settings: Battery Selection/Absorption Charge and Functional Settings
Battery Type
Selection
Open Lead
(Default)
Float Charge/
Jumper Insert Position
5
1 2 3 4
Pos. 5
Pos. 1
1 2 3 4
5
1 2 3 4
5
57.6 VDC
Pos. 5
Pos. 2
1 2 3 4
5
1 2 3 4
54.5 VDC
Gel Battery
Insert Jumper: Pos. 3
5
57.6 VDC
54.0 VDC
Sealed Lead High
Insert Jumper: Pos. 2
Pos. 5
None
1 2 3 4
53.5 VDC
Sealed Lead Low
Insert Jumper: Pos. 1
Absorption Charge Enable/
Jumper Insert Position
5
57.6 VDC
Pos. 3
1 2 3 4
5
Pos. 5
1 2 3 4
5
57.6 VDC
55.2 VDC
* Note: voltages above are at 20˚ C with no battery temp. sensor connected.
Function Setting
Battery Test ON
Insert Jumper: Pos. 4
Pos. 4
1 2 3 4
5
Insert jumper at position 4 to enable Periodic Battery condition
test process. (Fault reported by LED diagnosis blink code, see
Table 6):
t Battery wiring connection
t Battery efficiency/sulfation (impedance test)
t Shorted Cell
3
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
1) General Information
This DIN rail mount DC UPS Combines all system power functions: power supply, battery charger, UPS circuitry and status
monitoring in one compact unit that produces 48 volt, 5 amps allocated via outputs for load and battery:
• Load output: “load priority” distribution ensures power is dedicated first to the load, with remainder then allocated to
battery charging, thus preventing a discharged battery from impacting operation of critical loads.
• Battery output: 3 step charging for rapid battery recovery, programmable for battery type, with optional temperature
compensation sensor
• Battery automatically on line to support load anytime AC fails
• Low voltage disconnect protects battery from total discharge
• Automatic periodic battery health diagnosis
• High operating temperature range to 70˚ C
• Alarm contacts: AC fail, battery status/condition
Materials Provided:
1 ea. DIN-UPS unit with integral DIN rail mount clip
3 ea. Jumper tabs for programming
1 ea. Jumper wire (orange) for 115 volt input operation
Optional Equipment:
Temperature Compensation Sensor, P/N: 468-4510-0
2) Safety Information
WARNING – Explosion Hazard. Do not disconnect loads or battery unless AC input and battery have been
switched off.
WARNING – Explosion Hazard. Substitution of components may impair suitability for class I, Division 2.
WARNING – Switch off or remove AC input and battery power before wiring the DIN-UPS 48-5. Never work
on the DIN UPS when it is connected to AC input and battery. The DIN UPS must be installed in accordance
with UL508 or local electrical codes depending upon the application. The DIN UPS should have a suitability sized AC input
circuit breaker feeding its AC input. See specification section for maximum AC input draw for your input voltage for circuit
breaker sizing.
CAUTION: Hot surface. Avoid touching the DIN UPS case while operating at or near its full load capacity. Remove AC and
battery power and allow DIN UPS at least 10 minutes to cool before removing from DIN Rail.
3) Installation/Wiring
A) Mounting:
The unit is designed for 35 mm DIN rail mounting in an enclosure and relies on convection (free air) cooling, thus must
have a minimum vertical and horizontal distance to adjacent surface of 4” (10 cm) to this power supply in order to assure
sufficient air flow. Note, that depending on the ambient temperature and load of the device, the temperature of the case
can become hot to the touch.
The unit is designed for vertical mount (+/- 5˚) and has an integral clip on the back to secure it to the rail. To mount, place
the top tabs over the top of the DIN rail, and using a long slotted screw driver insert it in the groove at the bottom of the
bracket and twist which will extend the spring loaded mounting bracket downward allowing the unit to be positioned
against the DIN rail, release the bracket with DIN UPS positioned vertically and the rail will be captured and the unit
secured.
Figure 2: Mounting
A
Insert flat head
screwdriver in slot of
bottom tab and twist to
extend bracket
Figure 3: Removing
A
B
B
Twist
Twist
Insert flat head
screwdriver in slot of
bottom tab and twist to
extend bracket
4
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
B) Wiring
1. AC Input: Terminal Block (lettered left to right) - Figure 4
a) AC Hot (note: install jumper provided across terminals j1 and j2 for 115 VAC input)
b) Neutral
c) Earth Ground
j1 & j2) Jumper these two terminals for 115 VAC operation and apply 115V hot to term a and neutral to b
Recommended wire size: 16 AWG
Figure 4: AC Input Terminal Block
(714) 751-0488
[email protected]
automationdcpower.com
wport Beach, CA USA
AC INPUTS
L
N
a
b
Jumper FOR
115 Vac
j1
j2
c
2. Output
The unit has two outputs: one connects to the Load and the other to the back-up
Figure 5: Output Terminals
battery. Note: the unit has a load priority circuit, all produced power first is made available
to the load with remaining power made available for battery charging. The DIN UPS is
Load Output Battery Output
isolated from the case, thus you may apply to a positive or negative ground system.
Battery Output: See page 3, Section G for programming per battery type.
Output to Load: terminals for plus and minus.
1
2
OUT
LOAD
Fuse note: We recommend a 10 amp fuse be installed on the hot leg at battery.
Battery/Output wires size (recommended): 16 AWG
Terminal Block maximum wire size (recommended): 10 AWG
3
4
5
6
AC
FAIL
AC
FAIL
7
8
9
10
BATTERY
LOW BATTERY
OR BATTERY
REPLACEMENT
T
C) Alarm Contacts, Form C (Isolated):
Form C Contacts for remote monitor: Activate upon:
a. Main or back up power fail
b. Low battery, or poor battery condition
5
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
Table 2: Alarm Contacts
Figure 6: Alarm Contacts
Terminals, Form C (Isolated)
Contact
2
Fault
Battery*
LED
3
Diagnosis
LED
5-6
5-7
8-9
8-10
1
AC Fail
LED
AC only
closed
open
open
closed
off
on
2 Blink-Pause
AC + Batt
closed
open
closed
open
off
off
1 Blink/sec
Batt only
open
closed
closed
open
on
off
off
Low Batt
open
closed
open
closed
on
on
off
Input
5
6
7
8
AC
FAIL
9
10
LOW BATTERY
OR BATTERY
REPLACEMENT
* Labeled Low Battery or Battery Replacement on Front Panel
Figure 7: Status Indicator LEDs
Relay Contact Rating:
Max. DC: 30 VDC, 1 amp; AC: 60 VAC, 1 amp: Resistive load (EN 60947-4-1)
Min.1mA at 5 VDC
1
AC
FAIL
D) Optional Battery Temperature Compensation Sensor P/N: 468-4510-0
To install, remove the access tab in the front panel decal labeled
AUX 1, install the Temp. Sensor into the RJ-45 connector. Attach
sensor to side of battery using RTV silicone.
2
The sensor will vary the battery charging voltage depending on the battery’s
temperature and charge program setting.
3
LOW BATTERY
OR BATTERY
REPLACEMENT
i
Table 3: Absorption Charge Voltage & Float Charge Voltage Settings
DIAGNOSIS
Figure 8: Battery Temperature Sensor
Access Tab
Access
Tab
T
E
M
P
P
R
O
B
E
Float Voltage = Voltage @ 20° C - ( Sensor Temp ° - 20°) x .003 x number of cells)
Fast Charge = Voltage @ 20° C - ( Sensor Temp ° - 20°) x .005 x number of cells)
Eg. Sensor Temp = 60°
Voltage @ 20° = 53.5 (Open Lead)
Battery Cells = 24
Float: 50.64V = 53.5V - (40° x .003 x 24)
S 48-5
5 230Vac
If the battery temperature is less than -20° C or greater than +60° C, an ‘outside its range (temp. sensor)’ alarm is signalled
with code 7 blink.
If the sensor is not connected or if the sensor is defective, the LED Low Batt will illuminate and the LED Diagnosis’ LED
continues to show the status of the battery, i.e., trickle charge, fast charge or recovery charge.
Figure 9: Battery Type
4) Settings
OUTPUT: 48Vdc 5A
A) Battery Type/Charge Curve
Charge curve per battery type: via programing jumpers
insterted on bottom panel of unit right side.
4) 751-0488
@newmarpower.com
mationdcpower.com
t Beach, CA USA
AC INPUTS
L
Jumper FOR
115 Vac
N
Using programming jumper tabs provided and a small needle
nose pliers, insert programming jumpers to select float voltage
and enable absorption voltage per battery type. Caution, do
not program unit while connected to power.
Jumpers
Insert jumper
tabs for battery
selection on
bottom panel.
1 2 3 4
5
6
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
Table 4: Battery Selection/Absorption Charge
Battery Type
Selection
Open Lead
(Default)
Float Charge/
Jumper Insert Position
Absorption Charge Enable/
Jumper Insert Position
Pos. 5
None
1 2 3 4
5
1 2 3 4
53.5 VDC
Sealed Lead Low
Insert Jumper: Pos. 1
57.6 VDC
Pos. 5
Pos. 1
1 2 3 4
5
1 2 3 4
Pos. 5
Pos. 2
1 2 3 4
5
1 2 3 4
54.5 VDC
Gel Battery
Insert Jumper: Pos. 3
5
57.6 VDC
54.0 VDC
Sealed Lead High
Insert Jumper: Pos. 2
5
5
57.6 VDC
Pos. 3
1 2 3 4
Pos. 5
5
1 2 3 4
5
57.6 VDC
55.2 VDC
* Note: voltages above are at 20˚ C with no battery temp. sensor connected.
B) Battery Charge Current Limit/Battery Charge Level
Allows setting maximum current flow to battery during recharge cycle- use when low amp-hour batteries are applied to
system to prevent overheating when recovering dead batteries. Adjustment range 20-100% of available charge current.
(Available charge current = unit output rating of 10 amps minus load demand. Note: the unit has a load priority circuit, all
produced power is made available to the load, remaining power is available for battery charging).
To set, use small slotted screw driver to rotate selector dial. Set dial between 10 to 20% of battery capacity (Amp Hours).
Figure 10: Current Limit/Battery Charge Level - Dial
C) System Settings
Via plug-in jumper programing terminals located on bottom right of the unit. Install jumper per illustration below to
Enable Battery Test.
Table 5: Functional Settings
Function Setting
Battery Test ON
Insert Jumper: Pos. 4
Pos. 4
1 2 3 4
5
Insert jumper at position 4 to enable Periodic Battery condition
test process. (Fault reported by LED diagnosis blink code, see
Table 6):
t Battery wiring connection
t Battery efficiency/sulfation (impedance test)
t Shorted Cell
7
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
5) Operation
Figure 11: Status Indicator LEDs
A) Status Indicator LED’s
1. Power source: Mains or back up
i. AC OK (AC Fail LED Off)
or
ii. AC Fail: Operating on battery backup power
(LED On) red
2. Low battery, or battery replacement
1
AC
FAIL
2
LED illuminates when:
• Low Battery (capacity less than 30%)
• Bad connection to battery
• Battery requires replacement
LOW BATTERY
OR BATTERY
REPLACEMENT
3
i
3. Diagnosis LED.
DIAGNOSIS
Charger output status system diagnosis and Fault mode diagnosis: by
blink code (Table 6 below).
Table 6: Status Indicator LEDs
Monitoring Control
Charging Type
System Auto Diagnosis
State
LED Diagnosis (No.8)
LED Battery Fault No.7)
Float
1 Blink/sec
OFF
Absorption
2 Blink/sec
OFF
Bulk
5 Blink/sec
OFF
Reverse polarity or
high battery Voltage
1 Blink/pause*
ON
Battery Not connected,
no output power
2 Blink/pause
ON
Battery shorted cell
3 Blink/pause
ON
Over Load or short
circuit on the load
4 Blink/pause
ON
Bad battery; Internal
impedance Bad or
Bad battery wire
connection
5 Blink/pause
ON
Battery Life test not
possible
6 Blink/pause
ON
Temp. Sensor outside
its range
7 Blink/pause
ON
Boost condition; battery 8 Blink/pause
discharge after 4 min.
of overload.
ON
Internal fault
9 Blink/pause
ON
Low battery detected
when system
activated by battery
start button with no ac
input
10 Blink/pause
ON
Life test not possible;
Parallel mode on Slave
Device
12 Blink/pause
Bad battery wire
connection; Parallel
mode on Slave Device
13 Blink/pause
* Pause: 1 Second
8
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
B) LVD)
The unit contains a low voltage load disconnect that activates at 36 volts (1.5 vpc) which is factory set and cannot be user
modified.
6) Protection
On the AC Input: the device is equipped with an internal fuse. If the internal fuse is blown, it is most probable that there is
a fault in the unit. If this occurs, the unit must be returned to the factory.
On the DC Ouput Battery and Load: The device is electrically protected.
Reverse polarity: the module is automatically protected against reverse of battery polarity and connection of reverse
polarity.
Over current and output short circuit: the unit limits the output current. Low voltage disconnect protects battery from deep
discharge.
Thermal protection
Operating temperature range -12 to 70˚ C. Unit will produce full rated power on continuous basis to 50˚ C, however;
system load must be reduced by 2.5% per 1˚ for continuous operation above 50˚ C. If the temperature reaches 70˚ C, the
unit will reduce its maximum output to approximately 50% of its rating. If the temperature exceeds 70˚ C, the unit will shut
off and restart once temperature drops.
7) Specifications
Input:
Voltage: 90-135/ 180-305 47-63 hz
Amperage: 3.3 @ 120 VAC / 2.2 @ 230 VAC
Output: 48 volts, 5 amps total available to power loads and charge battery, with load priority distribution.
Peak: 15 amps 4 seconds (with battery power boost)
Low Voltage Disconnect Point: 36 VDC
Output ground isolated from case, may be used in positive ground applications. LVD function is lost
Front Panel LED Indicators:
• Power Source: operating on back up – red LED
• Battery and System Diagnostics (via blink code)
Settings/Selectors:
• Battery Type: AGM (Sealed Lead High), Sealed Lead (Low) Acid, Gel-Cell & Open Lead (Flooded Cell)
• Battery Charge Current Limit: 20 - 100% of charge amperage rating
Alarm Contacts (form C): Active:
• On back-up power/AC Fail
• Battery abnormal condition (summary contact): Discharged, damaged, disconnected, sulfated/short circuit, reverse
polarity, bad thermal sensor
Operating Temperature: -12 to 70˚ C. Continuous to 50˚, de-rate 2.5% per˚ C >50˚ C
Cooling: Free air convection
Efficiency: ≥83%
Humidity: to 95%, to 25˚ C
Protection:
• Low Voltage disconnect at 1.5 volts per cell (36 VDC)
• Internal fuse
• Current limiting
• Short circuit
•
•
•
•
Reverse polarity
Thermal overload shut down and recovery
IP 20
Designed to UL 1950
Terminal Blocks: Screw type
Mounting: DIN Rail Bracket 35 mm
9
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
8) Troubleshooting
Symptom
Possible Cause
Corrective Action
1.Reduce load or split load between
two separate DIN UPS units
A. Battery requires excessive
re-charge time
1.Load at or near max.
recommended load providing
minimal current available for
charging
2.Charging level current set to low
2.Adjust “Battery Charging Level”
control knob to higher level
1.Time buffer set to incorrect position
1.Verify correct setting with manual
2.Batteries not charged, due to high
load demand
2.Reduce load or split load between
two separate DIN UPS units
1. Absorption jumper not installed
1. Install provided jumper in
position 5
D. Unit does not turn on
1. AC input is 115 VAC, no
jumper wire installed
1. Install 115V jumper wire across j1
and j2
E. Trips AC input breaker
1. AC shorted to case
1. Verify correct AC input wiring
B. Load turns off after a couple
of seconds when running
on battery
C. No absoprtion voltage
2. Defective unit
2. Contact technical service
1. DC output wired backwards
or shorted
1. Remove AC input and check DC
wiring
2. No AC input
2. Verify correct AC input and
jumper wire installed if powering
from 115 VAC
3. Excessive temperature or
blocked ventilation
3. Improve ventilation, unblock
vent holes
F. No output
G. No voltage on battery
output terminals
H. Diagnosis LEDs always blinking
4. Defective unit
4. Contact technical service
1. No battery installed (voltage
required for battery output to
turn on)
1. Install batteries
2. Missing or blown battery
wiring fuse
2. Replace missing or blown battery
wiring fuse
1. Normal operation
1. Refer to Chart 2: Diagnosis Table
Section
9) Warranty
Newmar warrants that the DIN-UPS 48-5 DIN Rail UPS to be free from defects in material and workmanship for two years
from date of purchase. If a problem with your DIN-UPS 48-5, or if you have any questions about the installation and proper
operation of the unit, please contact NEWMAR’s Technical Services Department:
Phone: 714-751-0488 - From the hours of 7:30 a.m. to 5:00 p.m. weekdays, P.S.T.;
Fax: 714-957-1621
E-mail: [email protected]
10
P.O. Box 1306
Newport Beach
California 92663
Automation DC Power • Powering the Network
www.Newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]

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