Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. +39 0522 345518 – Fax +39 0522 345551 – mail: info@adelsystem.it
www.adelsystem.com
Instruction Manual All In One_r17.doc
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All In One: U
ninterruptible
P
ower
S
upply
Output Vdc
Thank you for having chosen one of our products for your work.
We are certain that it will give the utmost satisfaction and be a notable help on the job.
General Description
Thanks to the All In One units (DC-UPS), it will be possible to optimize
power management. The available power is automatically allocated
between load and battery, supplying power to the load is the first priority
of the unit thus it is not necessary to double the power, because also the
power going to the battery will go to the load if the load so requires. The
maximum available current on the load output is 2 times the value of the
device rated current In. We call “Battery Care” the concept base on
algorithms that implement rapid and automatic charging, battery charge
optimization during time, flat batteries recovery and real time diagnostic
during installation and operation. The Real Time Auto-diagnostic system,
monitoring battery faults such as, battery Sulfated, elements in short
circuit, accidental reverse polarity connection, disconnection of the battery, they can easily be detected and
removed by help of Blink Code of Diagnosis Led; during the installation and after sell. The continuous monitoring of
battery efficiency, reduces battery damage risk and allows a safe operation in permanent connection. Each device
is suited for all battery types, by means of jumpers it is possible setting predefined curves for Open Lead Acid,
Sealed Lead Acid, Gel, Ni-Cd, Ni-Mh(option). They are programmed for two charging levels, boost and charge, but
they can be changed to single charging level by the user. A rugged casing with bracket for DIN rail mounting
provide IP20 protection degree. They are extremely compact and cost-effective.
Main Characteristic
•
Input: Single-phase
115 – 230 Vac
•
Output Load: power supply:
24 Vdc; 3, 5, 10, 20 A; 12
Vdc; 3, 6, 10, 35 A 48 Vdc; 5 – 10 A
•
Output Battery: charging
24 Vdc; 3 – 5 – 10 – 20 A;
12 Vdc; 3 – 6 – 10 – 35 A; 48 Vdc; 5 – 10 A
•
Suited for the following battery types: Open Lead Acid,
Sealed Lead Acid, lead Gel and Ni-Cd
•
Automatic diagnostic of battery status. Charging curve
IUoUO, constant voltage and constant current Battery Life
Test function (Battery Care)
•
Switching technology-
•
Three charging levels: Boost, Trickle and Recovery
•
Protected against short circuit, Over Load and inverted
polarity
•
Signal output (contact free) for discharged or damaged
battery
•
Signal output (contact free) for mains or Back-UP
•
Protection degree IP20 - DIN rail; Space saving
Safety and warning notes
WARNING
– Explosion Hazard Do not disconnect Equipment unless power has been switched off or the area is
known to be non-hazardous.
WARNING
– Explosion Hazard. Substitution of components may impair suitability for class I, Division 2.
WARNING
– Switch off the system before connecting the module. Never work on the machine when it
is live. The device must be installed in according with UL508. The device must have a suitable isolating
facility outside the power supply unit, via which can be switched to idle. Danger of fatal Injury!
Connection (terminal and wiring):
Cable Connection:
The following cable cross-sections may be used:
Solid
(mm
2
)
Stranded
(mm
2
)
AWG
Torque (Nm)
Stripping
Length
All In One
(Size)
1 Phase L N PE
Input AC
1 Phase L N PE
Input AC
0.2 – 2.5 0.2 – 2.5
24 – 14 0.5 – 0.6 Nm
7 mm
Size 1 and 2
In:
4.0
6.0
30 – 10 0.8 – 1.0 Nm
7 mm
Size 3
0.2 – 2.5 0.2 – 2.5
24 – 14 0.5 – 0.6 Nm
7 mm
Size 1 and 2
Out:
4.0
6.0
30 – 10 0.8 – 1.0 Nm
7 mm
Size 3
Signal: 0.2 – 2.5 0.2 – 2.5
24 – 14 0.5 – 0.6 Nm
7 mm
All types
The connection is made by the screw type 2.5 mm
2
or 4.0 mm
2
(CBI2420A – CBI1235A) terminal blocks. Use only
copper cables that are designed for operating temperatures of > 75 °C. Wiring terminal shall be marked to indicate
the proper connection for the power supply.
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Output Load (Main input ON)
The output Load in normal mode, Main Input Vac Voltage present, follow the charging battery dc output voltage. The
minimum and maximum range stabilized are the following:
- CBI12xx:11 – 14,4 Vdc; (Without battery connected out. Voltage fixed at 12Vdc)
- CBI24xx:22 – 28.8 Vdc; (Without battery connected out. Voltage fixed at 24Vdc)
- CBI48xx:44 – 57.6 Vdc; (Without battery connected out. Voltage fixed at 48Vdc)
Thanks to the All In One units, it will be possible to manage the power. The available power, is automatically
allocated between load and battery: supplying power to the load is the first priority of the unit; thus it is not necessary
to double the power, and also the power available for the battery will go to the load if the load requires so:
in “Power Boost Mode” the maximum current on the load output is the 2 times the rated current 2 x In (I
load
= I
n
+ I
batt
)
in continuous operation and 3 times the rated current 3 x In (I
load
= 2I
n
+ I
batt
) for 4 seconds; after this parameter the
devices is electrically protected against overload and short circuit.
- In “Power Boost Mode”, if the current of the battery generate current to the load for a time more than 4 minutes, the
device give message (8 Blink), consequently means that the battery it is going to unloading.
- If the Main Input Voltage fall below a Threshold level (50% of the Typ. Vac input) the battery it is immediately
connected to the Output Load, without any interruption.
- voltage dips: In this situation the voltage in the output load it is the same of the battery.
-
To Avoid deep battery discharge,
the battery will supply the load until battery voltage reaches 1.5 V/cell. Below
this level the device automatically switches off to prevent Deep discharge and battery damage.
Output Load In Buffer Mode (Main input OFF)
Some example of buffering time depending on LOAD Output in function to the Ah of the battery.
Buffering
Time
BATT1.2 Ah BATT 3 Ah
BATT7.2 Ah
BATT12 Ah
BATT100 Ah
Load 1.5 A
20 min
60 min
200 min
400 min
/
Load 3 A
8 min
30 min
120 min
240 min
/
Load 5 A
3 min
15 min
55 min
100 min
/
Load 7.5 A
2 min
10 min
30 min
60 min
/
Load 10 A
No
7 min
20 min
45 min
20 h
Load 12 A
No
3 min
12 min
30 min
600 min
Load 15 A
No
No
9 min
20 min
400 min
Load 20 A
No
No
7 min
13 min
240 min
Operating and Display Element:
No. 10: Input AC Port pin. L – N:
1 Phase Switching Power Supplies L, N, PE .
Size 2 and Size 3 BRIDGE ONLY for input 115 Vac, and connect L, N, PE .
No. 3: Battery Connection Port:
Connect the battery between pin. 3 (–) and 4 (+)
One battery (12 Vdc) for CBI12xx;
Two battery (12 Vdc) connected in Series for CBI24xx;
Four battery (12 Vdc) connected in Series for CBI48xx;
No. 4: Output Load:
Connect this Output to the load 1 (-). 2 (+).
3
4
5
6
7
8
10
11
2
1
12
9
13
14
Size 1
Size 2
Size 3
11
12
12
10
10
3
4
4
3
11
9
15
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No. 12: Battery Management Configurations
Preliminary Operations: One device for all battery types.
Completely automatic, all devices are suitable to charge most batteries types thank to User Selectable charging
curves. They can charge open lead acid, sealed lead acid, Gel and Ni-Cd, Ni-MH batteries. It is possible to change
or add other charging curves connecting the device to a portable PC.
Caution: Switch off the system before Setting the jumper. Only jumper in position 5 Refresh ON/OFF state whit
Power.
Battery Type
Selection
Jumper Position
(Size 1 and Size 3)
Jumper Position
(Size 2)
Trickle/Float charge
(Volt/Cell)
Fast/Bulk charge
(Volt/Cell)
Open Lead
2.23
2.40
Sealed Lead Low
2.25
2.40
Sealed Lead High
2.27
2.40
Gel Battery
2.30
2.40
Gel Battery (1)
2.30
2.40
NiCd – NiMh (1)
10% Imax Trimmer
1.70–(12V);1.5–
(24V)
Functional Setting
Function
Battery Life test ON
Jumper present:
Life test enabled.
Fast Charge Enable
Jumper present:
fast charge enabled.
“Battery Start”
(without Input Main)
(2)
RTCONN cable for connection to external
Push bottom mounted on front Panel of the
external system.
Fast Recovery
Charge (3)
Not available
Jumper present: Fast Recovery Charge,
enabled only for Size 3. Possibility to
recharge the battery also when the voltage is
close to Zero with the maximum power of the
device. To be careful, the Load Output
voltage follow the voltage of the battery.
Notice:
1
Be care full, in NiCd-NiMh Option, the Sealed Lead High charging curve is deleted.
NiCd-NiMh (Options to be defined by Order). End-of-charge determined by negative
∆
V detection of battery
voltage (-5mV/cell). If no negative
∆
V but only a “flat” profile is detected fast charge is terminated after 10 min.
General end-of-charge timeout set to 16 hours. Trickle charge current is regulated at 10% of max current
corresponding to trimmer position. In order to detect end-of-charge negative
∆
V, charging current must be set at
least at 30% of nominal battery capacity (0,3 C); with lower values of charging current negative
∆
V detection is
not guaranteed.
2
Don’t leave the juper in position 5; penalty discharge in Back up mode completely the battery close to Zero.
For Size 2: must be require CBI2410A/S or CBI485A/S ( /S means start with battery functions, otherwise only
start with Input Main)
3
Jumper selection n.7 is available only on CBI 420W and 480W (Size 3)
No. 5: Charging Level Current:
It is possible set the max recharging current for the batteries by trimmer (Charging
Level). The current adjustment goes from 20% ÷ 100% of In. Set the maximum charging
current between 10% and 20% of the battery capacity.
No. 11: Auxiliary Output
RJ 45 behind the label in SIZE 1 and SIZE 3; remove the window label to find the connector,
For SIZE 2: CBI2410 and CBI485 require /ARJ code for RJ45 connector.
It is possible connect:
•
Temperature sensor, for ambient temperature charging
compensation. With this it is possible to active the
specifications of the EN54-4 firing norm.
•
Connection for external display to remote N° 3 led of the internal
device.
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Charging Curve
Automatic multi-stage operation and real time diagnostic allows fast recharge and recovery of deep discharged
batteries, adding value and reliability to the system hosting the CBI device. The type of charging is Voltages
stabilized and Current stabilized IUoUo.
Three charging modes are identified by a flashing code on a Diagnosis LED.
To maintain the Output Load in lower Voltage state, don’t put jumper in position 5, in this case no boost charge but
only Float charge.
State
Diagnosis LED
Battery Fault LED
Trickle
1 Blink/sec
OFF
Boost
2 Blink/sec
OFF
Charging Type
Recovery
5 Blink/sec
OFF
Compensation Recharges in temperature
(For SIZE 2: CBI2410 and CBI485 require /ARJ code)
Connecting to RJ45 Auxiliary Output the cable RJTEMP (supplied separately), the CBI will vary the voltage of battery
charging in depending of the temperature:
CBI Model
Fast Charge
Trickle charge
CBI12xx (12Vdc)
-2.5mV/°C
-1.5mV/°C
CBI24xx (24Vdc)
-5mV/°C
-3mV/°C
CBI48xx (48Vdc)
-10mV/°C
-6mV/°C
The sensor place on cable RJTEMP must be applied on the battery.
If the sensor is not connected or if the sensor is defective, the led Low Batt is on and the led Diagnosis continues to
show the status of the battery: trickle charge, fast charge or recovery charge.
Protection Features
On the primary side:
the device is equipped whit an internally fuse. If the internal fuse is activated, it is most probable
that there is a fault in the device. If happen, the device must be checked in the factory.
On the secondary side Battery and load:
The device is electrically protected against short circuits and overload.
Inversion polarity:
the module it is automatically protected against inversion of battery polarity and connection of load
inverted.
Over current and output short circuit:
the unit limits the output current (see the technical data).
Deep discharge :
not possible. The unit disconnects the battery when a minimum voltage level is reached.
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:
Output Power connections:
Normal connection
Typical application for All In One device, one output for Load
“DC Bus”, one Input/Output for connection to the battery.
N°1 battery (12 Vdc) for CBI12xx;
N°2 battery (12 Vdc) connected in Series for CBI24x x;
N°4 battery (12 Vdc) connected in Series for CBI48x x;
Parallel connection “Redundancy”
Power supplies can be paralleled for 1+1 redundancy to
obtain a higher system availability. Redundant systems
require a certain amount of extra power to support the load in
case one power supply unit fails. The simplest way is to put
two CBI in parallel. In case one power supply unit fails, the
other one is automatically able to support the load current
without any interruption. This simple way to build a redundant
system has two major disadvantages:
-
The faulty power supply can not be recognized.
- The Diagnosis LED will give the informations about the status
of the Load and the Battery (see Display Signals for more
data).It does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a
-virtually nearly impossible - case, the defective unit becomes a load for the other power supplies and the output
voltage can not be maintained any more. This can only be avoided by utilizing decoupling diodes which are
included in the Redundancy Module MR220. Recommendations for building redundant power systems: a) Use
separate input fuses for each CBI. b) Monitor the individual CBI units by three LED. Each unit has two relay: Mains
or backup and Low Battery or Battery Replacement (faulty situation). This feature reports a faulty unit; see Relay
Contact Rating for any technical detail. c) When possible, connect each power supply to different phases or
circuits.
Parallel connection “Double Power”
Power supplies can be paralleled for 1+1=2 parallel to obtain a
the double power of a single unit. The possibility to put in
parallel connection it is only in SIZE 3 devices, to be reach the
sum of the current at the same output voltage. It is necessary
to use a standard UTP cable RJ45 to connect Aux2 of each
device. The communication protocol is based on CAN2.0A
standard. In this way the system have only One output for the
Load and One output for the battery. a) Use separate input
fuses for each CBI. b) Configure one unit as master and the
other as slave (see “master/slave network configuration”). User interface elements (jumpers, charging level
trimmer, start button, time-buffering rotary switch, thermal sensor, relays) must be used on master only, not on the
slave. Set charging level trimmers at the same level both on master and on slave. In this configuration mode, only
the Master device give Display status Led indications and Signal port output mains/backup and low battery. Don’t
use Slave device for signal status but only for Power unit, only the Led Diagnosis it is always ON to identify the
Slave Device.
Master/slave network configuration
1. Switch off the units and connect RJ45 cable in
Aux 2
2. Set rotary switches“Time Buffering” in, master: 0;
slave: 1
3. Switch on the units together; hereafter the rotary
switch on Master device, is available for Time
Buffering setting.
The network remains so configured as long as RJ45
cable remains connected. If you want to reconfigure
the network:
4. Switch off the units and disconnect RJ45 cable;
5. Switch on the units together
6. Go back to point 1.
For Start Battery without mains voltage, push start
button only on Master (the Slave will powerup
sequentially).
In such double power connection, all battery tests are
under master control and synchronization
Serial connection:
a) It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed 150Vdc.
b) Voltages with a potential above 60Vdc are not SELV any more
and can be dangerous. Such voltages must be installed with a
protection against touching. c) For serial operation use power
supplies of the same type. d) Earthing of the output is required
when the sum of the output voltage is above 60Vdc. e) Keep an
installation clearance of 10 mm (left/right) between two power
supplies and avoid installing the power supplies on top of each
other. Note: Avoid return voltage (e.g. from a decelerating motor
or battery) which is applied to the output terminals.
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No. 1, 2 Signal Ports (output Isolated):
Connections for,
No. 2: Main/Back Up: Input Main On/Off. Contact: 5,6,7
No. 1: Low Battery, Fault connections systems, Battery replacement. Contact: 8,9,10
Relay Contact Rating:
Max.DC1: 30 Vdc 1 A; AC1: 60 Vac 1A : Resistive load (EN 60947-4-1)
Min.1mA at 5 Vdc: Min. permissive load
Signal Output port true
table:
Port N°2 - Led N°6 Main/Back-
Up
Port N°1 - Led N°6 Fault
Battery
5-6 Closed
5-7 Closed
8-9 Closed
(OK)
8-10 Closed
ON
- led off
- led off
Main Input Vac
OFF
- led On (1)
- led off
YES
- led On
- led On
The battery in
BackUP it is less than
30% cap?
NO
- led On
- led off
YES
- led off
- led On (2)
Battery or system
Fault?
NO
- led off
- led off
Note:
(1) For better efficiency of the system, filter relay Main/Back up with a delay of at least 5 seconds before give alarm
Main Lost, example: connection to PLC.
(2) See Diagnosis Led
No. 6, 7 and 8 Display Signals
No.6: Led Main/Back Up: Input Main On/Off
No.7: Led Low Battery(capacity less than 30%), Fault connections systems, Battery replacement.
No.8: Led Battery charge mode,
Led Diagnosis. Diagnosis of the system through “blinking code” signal
Monitorin
g Control
Chart:
State
LED Diagnosis
(No.8)
LED Battery
Fault (No.7)
Trickle
1 Blink/sec
OFF
Boost
2 Blink/sec
OFF
Charging
Type
Recovery
5 Blink/sec
OFF
Reverse polarity or high battery Voltage (over 32.5Vdc for
CBI24xxA)
1 Blink/pause
ON
Battery No connected
2 Blink/pause
ON
Element in Short Circuit
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
Life test not possible
6 Blink/pause
ON
Bad thermal sensor
7 Blink/pause
ON
Boost condition; battery discharge after 4 min. of overload. 8 Blink/pause
ON
Internal fault
9 Blink/pause
ON
Low battery (under 18.5Vdc for CBI24xxA) Only if started
from battery, no Main input. Form Jumper N°5 or Pus h
Bottom
10 Blink/pause
ON
CAN bus error
11 Blink/pause
Life test not possible; Parallel mode on Slave Device
12 Blink/pause
Bad battery wire connection; Parallel mode on Slave
Device
13 Blink/pause
Auto
diagnosis
of the
system
Boost condition; battery discharge after 4 min. of overload;
Parallel mode on Slave Device
15 Blink/pause
No. 9, 12: Start from Battery, No Main Vac
No. 9: Push-bottom, for 3 sec., in the front panel for switch ON the system without the “Main input Vac” but
only the battery connected. ( Not present in CBI2410XX and CBI485XX)
No.12: (Jumper n.5) It is also available the same function for remote start from the battery, via RTCONN
cable connected in the Push bottom mounted on front Panel of the external system. Standard function for all
products, Size 2 only with code CBI2410A/S and CB485A/S.
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No. 13: Time Buffering Setting
Time buffering it is enabled when the Input main is switched OFF. It is possible setting by the position of the rotate
switch present in model SIZE 3, for the other devices, must require the time buffering fro the factory.
The output LOAD time ON depending on position of the Switch.
Switch positions:
Switch position
0
1
2
3
4
5
6
7
8
9
Time Buffering (min.)
0.5
2
5
10
15
20
30
45
60
If the switch is in 0 position the Time Buffering maintain ON state until the battery it is completed discharged. Anyway
to prevent risk of damage, the product disconnect the batteries when a minimum voltage level is reached.
No. 14: Auxiliary Output “Aux 2”
Present only in CBI2420A and CBI1235A it is provided of CAN2.0A connection.
Connection for external Intelligent display.
No. 15: Auxiliary Output “Aux 3”
Present only in CBI2420A and CBI1235A : Not used.
Battery Care
The Battery Care philosophy is base on algorithms that implement rapid and automatic charging, battery charge
optimization during time, flat batteries recovery and real time diagnostic during installation and operation. The Real
Time Auto-diagnostic system, monitoring battery faults such as, elements in short circuit, accidental reverse polarity
connection, disconnection of the battery, they can easily be detected and removed by help of Blink Code of
Diagnosis Led; during the installation and after sell. Each device is suited for all battery types, by means of jumpers it
is possible setting predefined curves for Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd(option).They guarantees
battery reliability in time by continuously testing the internal impedance status, avoids any possible risk of damages
and grants also a permanent, reliable and safe connection of the battery to the power supply. The system, through a
battery stimulation circuit with algorithms of evaluation of the detected parameter, is able to recognize sulphated
batteries or batteries with a short-circuited element.
Battery Test: Automatic. Every 60 sec. check battery connection. Every 220 minute in trickle charge, make the test of
the battery efficiency. The fault is signalized with relay commutation and diagnosis led blinking.
Diagnostic Type Checks:
Check for accidental disconnection of the battery cables:
All In One detects accidental disconnection and immediately switched off the output power.
Battery not connected:
If the battery is not connected no output power.
Test of quality wire connections:
During trickle charge the quality (resistance) on the battery connection is checked every 20 sec. This to detect if the
cable connection has been properly made.
Battery in Open Circuit or Sulphated:
Every 220 minute. All In One tests of internal impedance, in trickle charging mode.
Reverse Polarity check:
If the battery it is connected with inverted polarity, All In One is automatically protected.
Test of battery voltage connections:
Appropriate voltage check, to prevent connection of wrong battery types, more or less than the nominal voltage.
End of Charge check
When the battery it is completely full, the device automatically switch in trickle charging mode.
Check for Battery Cells in short circuit
Thanks to specific algorithms of evaluation, the CBs recognize batteries with cells in internal short circuit.
In trickle charge every 2 hours test of element in short circuit.
Diagnosis of battery and device
All CBI devices support the user during installation and operation. A Blink code of Diagnosis Led allows to discriminate
among various possible faults.
Error conditions, “LED Battery Fault” ON and “LED Diagnosis” blinking with sequence; see Display Signal section.
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Thermal behaviour
Surrounding air temperature 50°C. For ambient tempe rature of over 50°C, the output current must be red uced by
2.5% per °C. Max 70°C At the temperature of 70°C th e output current will be 50% of In. The equipment does not
switch off in case of ambient temperature above 70°C or thermal overload. The devices are protected for Over
temperature conditions “worst case”; in this situations the device Shut-down the output and automatic restart when
temperature inside fall.
Standards and Certification
Electrical Safety:
Assembling device: UL508, IEC/EN 60950 (VDE 0805) and EN 50178 (VDE 0160).
Installation according: IEC/EN 60950.
Input / Output separation: SELV EN 60950-1 and PELV EN 60204-1. Double or reinforced insulation.
EMC Standards Immunity:
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5.
EMC Standards Emission:
EN 61000-6-4, EN 61000-6-3, EN 61000-3-2 (see data sheet for each device)
Standards Conformity:
Safety of Electrical Equipment Machines: EN 60204-1.
The CE mark in According to EMC 2004/108/EC and Low voltage directive 2006/95/EEC
Norms and Certifications
In Conformity to: IEC/EN 60335-2-29 Battery chargers; EN60950 / UL1950; Electrical safety EN54-4 Fire Detection and
fire alarm systems; 89/336/EEC EMC Directive; 2006/95/EC (Low Voltage); DIN41773 (Charging cycle); Emission: IEC
61000-6-4; Immunity: IEC 61000-6-2. CE.
Rail Mounting:
All modules must have a minimum vertical and horizontal distance of 10 cm to this power supply in order to
guarantee sufficient auto convection. Depending on the ambient temperature and load of the device, the
temperature of the housing can become very high!
