Operating Instructions “AKKUTEC” (NBPA 2440
Contents
1. mA aasma Netz Net vun Batt Us oe oe Bott wo e E Tobe bebe gee 22 LeeLee pos J eol lezeo Fi F2 Jn Die Anschl sse 2 y der I0 2 d rfen TO 7 62 Pa a n Ean Aer verbunden werden D oUa N o Ua The connections labelled 2 on the IO 2 interface are connected internally with Ua To avoid the creation of earth loops the connections labelled 2 on IO 2 must not be connected together A connection here can result in damage to the AKKUTEC units Protection of the battery circuit 1 and battery circuit 2 Attention The protection components overload and short circuit protection are to be installed as close as possible to the set of batteries for safety reasons Attention In the case of an overload the DC output current is the sum of the charging rectifier current and the battery current To protect the DC output circuit from overload it is necessary to use external fuses Decoupling diode module Attention The decoupling diode module must be designed for the sum of both AKKU7EC output currents 80 A Overload short circuit current AKKUTEC module with special parameter settings as Redundant Module 1 ID code 0 as well as Redundant Module 2 ID code 1 The complete samplin2. 290 0 220 0 290 0 U U ED AKKUTEC a al CED AKKurec caine D a 2 A m m D NIN Netz Net B Bott Ua Bott U E E T eres S T T A 20808 0Q 9 2o 2 22 2 IZO 0 0 22 222 a i Einbautiefe 147mm mit Klemmen Einboutiefe 150mm mit Klemmen mounting depth 147mm with terminals mounting depth 150mm with terminals To attach the AKKUTEC module directly on the mounting plate you can purchase optional mounting flanges 10 Battery Replacement Battery replacement is only permitted to be performed by authorised service personnel It is to be ensured that the battery poles are connected correctly In the case of batteries connected with the poles reversed battery charging and battery enable during mains failure is inhibited this is indicated by the simultaneous illumination of the Netzbetrieb Mains Operation and Fehler Fault LEDs Never short circuit batteries Risk of arcing and burns Never connect together new and used batteries or batteries of different types or from different manufacturers Used batteries are to be disposed in an environmentally responsible manner 11 Maintenance To ensure adequate backup capacity of the power supply the capacity of the b atteries should be checked at regular intervals of 3 to 6 months Checking the battery Force battery operation by switching off the mains The batteries must achieve the required
3. re Bott Uo vik r Bott Ua 2 ad jo0o0e0e B 2 2 aada EE a 2 2 2l SS SS F1 F3 Ua AD LZ KI A o Ua o Bott F2 C o Batt In the case of the master slave configuration the internal battery reverse pole connection protection is ineffective Reverse connection of the battery results unavoidably in damage to the loads and the AKKU TEC units To exploit the maximum effectiveness from the active current distribution the Ua cabling between the two modules should be made as symmetrical as possible cable length cable cross section Component Label 24V DC battery circuit contactor with switching current gt 30A DC Free wheeling diode for battery circuit contactor Attention Never operate the contactor without a free wheeling diode Operation without a free wheeling diode can result in irreparable damage to the AKKUTEC module Fuse protection for battery circuit contactor Attention In the case of an overload the DC output current is the sum of the charging rectifier current and the battery current To protect the DC output circuit from overload it is necessary to use external fuses Backup battery A
4. J Schneider Elektrotechnik GmbH P33G1D02 050202 doc Operating Instructions AKKU 7EC NBPA 2440 P33G1 Placing in operation and maintenance only by suitably qualified personnel The operating instructions are to be read prior to usage or installation of the AKKU TEC the information given is to be observed In the case of failure to observe the information given all rights under the warranty may be lost Safety Instructions Power supply for protection class I and enclosure rating IP20 Operation only in dry rooms Observe applicable VDE regulations in particular VDE 0100 and EN 60204 The surrounding air temperature range is to be observed To prevent overload of the DC output circuit the circuit is to be protected externally with a fuse Value see Section 3 1 Only the battery types specified for the unit are permitted to be used Battery replacement is only to be made with the unit unpowered See Section 10 On the connection of external backup batteries battery protection must be provided by the user In this case the protection componenis overload and short circuit protection must be installed as close as possible to the set of batteries for safety reasons On the usage of batteries sufficient air flow in accordance with VDE 0510 part 2 must be ensured Never connect together new and used batteries or batteries of different types or from different manufacturers Dispose of used batteries
5. 49 0 781 25318 Bettina Schneider Dipl Betriebswirt BA Postfach 2327 www j schneider de Rolf Anti Dipl Wirt Ing FH Pr pE Neta D 77613 Offenburg info j schneider de Amtsgericht Offenburg HRB 758 amp J uI J Schneider Elektrotechnik GmbH i a P33G1D02 050202 doc 5 Connection Prior to connection the values for the mains voltage and frequency are to be checked against the values on the rating plate Connect in accordance with the labels on the connecting terminals See main block diagram and connector assignments Unused connecting terminal screws are to be tightened Anschlu Klemme Starkladung Boost Charging Netz Mains L N Signal Contact Fehler Fault DC Output loads Connecting terminal Sammelstormeldung 5 NC 6 NO 7 COM Ua Signal Contact Netzbetrieb Mains ee ee n several modules Shut Down Control Input Connecting terminal 10 13 Battery Temperature Sensor Connecting terminal Battery Current Measurement Connecting terminal optional module 10 11 2 optional module 10 3 1 2 Current Share Bus Connecting terminal Signal Contact Battery Voltage Above Connecting terminal in case of parallel connection of CS 1 i __ 10 3 3 4 Signal Contact Battery Voltage Within Connecting terminal i i 10 3 5 6 In the case of overload the DC output current comprises the maximum charging rectifier cur rent as well as the current from the battery
6. To prevent overload of the DC output circuit the circuit is to be protected externally Value see Section 3 1 LIH DH a o 7 tT oan 3 K bo J Loap Lae ae Net pc pd Z 5 L3H E a a een zA Ly Ba tt 1 LEAD ACID BATTERY anive er iif S lt Tregulators Ler CURREN SHARE BUS curcuit 4 2 uC ls eh 4 20mA BATT TEMP OPTION isolation barrier lt a SHUT DOWN K lt Th w k BOOS T CHARGE K Ha EA Levy CEH fe 30v DC 0 5A GENERAL ERROR K A K K J T g C LEK S 30V DC 0 5A MAINS OPERATION OPERATION AND DISPLAYPANEL g ga DISPLAY z 4 4 U H2 OPTIONAL lt es 0 20mA 1 BATTERYCURRENT MEASURMENT id 4 OPTIONAL K LED 3 30V DC 0 5A UBATT ABOVE Leoy HS 30V DC O 5A UBATT WITHIN 4 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Postfach 2327 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH f a N D 77652 Offenburg D 77613 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl BeeNeta www j schneider de Betriebswirt BA pe oO info j schneider de Rolf Anti Dip Wirt Ing FH ee Amtsgericht Offenburg HRB 758 J Sc
7. an appropriate current measurement transducer is required that is inserted in the battery cable With the aid of the Control and Display Panel described in Section 7 6 the battery current can then also be indicated on the display 8 Taking Out of Operation The unit is taken out of operation by removing the mains supply To prevent subsequent backup from the batteries the battery circuit must be opened by activating Shut Down See Section 7 4 The Netzbetrieb Mains Operation and Fehler Fault LEDs must go out Never undo electrical connections whilst the unit is in operation It also not permitted to make electrical connections whilst the unit is in operation 6 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Postfach 2327 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH E D 77652 Offenburg D 77613 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl pENet www j schneider de Betriebswirt BA on kc info j schneider de Rolf Anti Dipl Wirt Ing FH Reg Nr T Amtsgericht Offenburg HRB 758 J Schneider Elektrotechnik GmbH P33G1D02 050202 doc 9 Installation Drawings
8. non maintenance free batteries and must only be performed for a limited period The usage of boost charging in conjunction with closed maintenance free batteries is not permitted as here damage can be caused to the batteries 7 4 Shut Down To avoid discharging the backup batteries to the deep discharge limit unnecessarily it is possible to shut down battery operation early This is performed by applying a 24V DC control voltage to connection 3 on the IO 1 terminal strip 5 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Postfach 2327 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH f a N D 77652 Offenburg D 77613 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl pENet www j schneider de Betriebswirt BA on kc info j schneider de Rolf Anti Dipl Wirt Ing FH Reg Nr T Amtsgericht Offenburg HRB 758 J Schneider Elektrotechnik GmbH P33G1D02 050202 doc 7 5 Temperature Compensation optional module Lead batteries have a temperature coefficient of approx 4mV per C and cell The AKKUTEC final charging voltage is selected such that battery charging is provided over a temperature range of 15 40 C In applications with frequent and large temperature variations the charging voltage should be appropriately compensated to achieve optimal battery life Also particularly in the case of very low surrounding air temperatures Tu lt 15 C compensation should be perfor
9. KKUTEC module with standard parameter settings The complete sampling of the signal inputs and outputs is performed via the master module See also Section 3 4 For the connections for the Control and Display Panel K1 F1 F2 F3 G A1 2 Adresse Helmholtzstrasse 13 D 77652 Offenburg R as S O please refer to the appropriate handbook 8 Postfach 2327 D 77613 Offenburg Tel 49 0 781 206 O Fax 49 0 781 25318 www j schneider de info j schneider de FV Battery circuit protection Attention The protection components overload and short circuit protection are to be installed as close as possible to the set of batteries for safety reasons IG AKKUTEC module with special parameter settings as Slave Module The centralised fault indication signal from the slave module should be evaluated separately Selective fault localisation Subject to technical change Gesch ftsf hrer Karl Schneider Dipl Ing FH Bettina Schneider Dipl Betriebswirt BA Rolf Anti Dipl Wirt Ing FH Amtsgericht Offenburg HRB 758 as Reg Nr 2750 J Schneider Elektrotechnik GmbH 12 2 Example Circuit for Redundant Operation Increase in the System Reliability P33G1D02 050202 doc Al Systemi A2 System2 b AKKUTEC AKKUTEC
10. bridging time under nominal conditions When the deep discharge limit is reached the AKKUTEC switches off automatically The unit is to be cleaned at least once a year depending on the degree of soiling 12 Special Operating Modes The AKKUTEC is suitable for master slave operation as well as for redundant operation The require d operating mode is defined by the setting of the parameters in the unit and the external circuit see below The parameters in the AKKU7EC units are set with the aid of the Control and Display Panel optional module via the 10 2 interface If no control panel is available at the user the modules can also be purchased with the parameters set appropriately in the factory The parameters set can be seen on the additional label on the front of the module 7 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Postfach 2327 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH D 77652 Offenburg D 77613 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl www j schneider de Betriebswirt BA info j schneider de Rolf Anti Dip Wirt Ing FH Amtsgericht Offenburg HRB 758 J Schneider Elektrotechnik GmbH 12 1 Example Circuit for Master Slave Operation Increased Power Al MASTER A2 SLAVE D gt AKKUTEC EP AKKUTEC GG SEER HEHA SEES EEE
11. der Dipl www j schneider de Betriebswirt BA info j schneider de Rolf Anti Dipl Wirt Ing FH wa oe Amtsgericht Offenburg HRB 758 J Schneider Elektrotechnik GmbH 3 Technical Data 3 1 Electrical Data Input Voltage Range 360V 550V 400V 10 500V 10 Input Frequency 45 65 Hz Rated Input Current 2 75A AC 400V AC 2 2A AC 500V AC Output Voltage a 19 8 26 4V DC b 19 8 28 6V DC during activated boost charging or temperature compensation Final Charging Voltage 26 4 V DC 0 4 Charging Characteristic I U DIN 41773 1 Deep Discharge 19 8V DC 0 4 Protection and Load Shedding at Constant Current Limiting Battery Type Pb battery maintenance free 3 2 Indicators Netzbetrieb Mains Operation Green LED LED illuminates on e Mains operation i e Ue gt Vemin and Tint lt Tintmax Green LED Battery voltage within the monitoring window i e 21 6 lt Ugat lt 27V DC Green LED Battery voltage above the monitoring window i e U Batt 27V DC 2 Adresse Helmholtzstrasse 13 D 77652 Offenburg Postfach 2327 D 77613 Offenburg www j schneider de info j schneider de Tel 49 0 781 206 0 Fax 49 0 781 25318 P33G1D02 050202 doc Efficiency Ua 26 4V DC la Nenn and Ue 400V AC worst case Output Circuit Load Circuit Secondary Type of Connector Combicon screw terminal Primary 2 5mm Netz Mains Tightening torque 0 5 0 6Nm T
12. g of the signal inputs and outputs is performed separately See also Section 3 4 For the connections for the Control and Display Panel please refer to the appropriate handbook 9 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Postfach 2327 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH f a N D 77652 Offenburg D 77613 Offenburg Fax 49 0 781 25318 Bettina Schneider Dipl pENet www j schneider de Betriebswirt BA ee oO info j schneider de Rolf Anti Dip Wirt Ing FH Reg Nk a780 Amtsgericht Offenburg HRB 758
13. hneider Elektrotechnik GmbH P33G1D02 050202 doc 6 Placing In Operation The unit is switched on by the application of the mains supply The battery voltage must match the nominal voltage of the charging rectifier Never reverse the poles of the battery Never short circuit batteries Risk of arcing Check the connections for correctness prior to switching on for the first time Only make electrical connections with the unit unpowered 7 Operation Approx 2s after the switch on of the mains the output voltage is enabled and the loads connected supplied with power The back up battery is also charged This operating mode is indicated by the illumination of the green Netzbetrieb Mains Operation LED By removing the mains voltage or if the input voltage drops below the minimum the AKKU TEC switches over to battery mode The battery mode is indicated by the illumination of the Fehler Fault LED The Netzbetrieb Mains Operation LED is not illuminated in this case The illumination of an LED always results in the energisation of the corresponding signal relay See block diagram Section 5 The Fehler Fault LED has a centralised fault indication function The individual causes of malfunctions are described in Section 3 2 7 1 Battery Circuit Monitoring To check the capability of the UPS to provide back up the battery circuit is tested cyclically at intervals of 60s the first test is performed 60s after mai
14. in an environmentally responsible manne 1 Concise Description The battery backed up DC power supply in the AKKU7EC range uses the standby parallel principle of operation and in conjunction with a lead accumulator ensures that the DC power supply is reliably maintained in the case of a mains power failure The power supply has the following features Switched primary switched power supply with I V charging characteristic Microcontroller based battery management Temperature compensation for charging voltage by means of external sensor module optional module Display and control panel for switch cupboard door installation or surface mounting option TEC bus with RS 232 Interface optional module 2 Standards and Regulations Safety of power transformers power supply units and similar EN61558 2 17 VDE 0570 2 17 Particular requirements for transformers for switch mode power supplies Optocouplers for protective separation against electric shock requirements tests EMC EN 55011 1998 limit class A Group 1 EN 61000 3 2 and EN61000 3 3 limit class A EN50082 2 1995 Overall unit EN 50178 EN60950 cULus Listed UL508 CSA 22 2 File E237077 c US LISTED Industrial Control Equipment 2VD5 1 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Postfach 2327 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH D 77652 Offenburg D 77613 Offenburg Fax 49 0 781 25318 Bettina Schnei
15. med to ensure adequate b attery charging By connecting the external temperature sensor module option to terminal strip IO 1 connection 1 and 2 note poles temperature compensation is automatically activated For an surrounding air temperature variation of 0 40 C the final charging voltage and thus also the output voltage varies over a range of 27 3 26 2 V DC Battery temperatures above 45 C are indicated by the simultaneous illumination of the Fehler Fault and Netzbetrieb Mains Operation LEDs To obtain satisfactory battery life the operating temperature of the batteries should not exceed 20 C Higher temperatures lead to a drastic reduction in the life 7 6 Control and Display Panel optional module can be connected to AKKU TEC equipment using the option interfaces 10 2 and 10 3 Particularly in larger battery system it is often desired to display equipment parameters e g battery voltage load current battery current error messages etc and to make parameter settings To meet these requirements a special door mounting display and control panel is available This panel has an illuminated LC display and a keypad setting parameters and operation The panel is connected to the IO 2 interface using two cables 7 7 Battery Current Measurement optional module can be connected to AAKU 7EC equipment using the option interfaces 10 2 and 10 3 To measure the battery current charging and discharging current
16. n of the UPS mode Switched input referenced to earth switching level 24V DC 16 80V DC Starkladung Boost Charging Activation of boost charging boost charging voltage 28 6V DC Switched input referenced to earth switching level 24V DC 16 80V DC 1 The signal contacts are coupled to LEDs see Section 3 2 The illumination of an LED thus results in the energisation of the corresponding relay 3 5 General fixation Fixation bar according to Pawan apa Individual Module Approx 3 3kg Permissible 0 50 C Alternative Adapter kit for Operating Temperature Recommended 10 20 C the direct fixation on the battery life mounting plate Permissible 0 40 C Dimensions B x H x T 290 x 180 x 147 mm See Section 9 4 Installation The battery backed up DC power supply is to be installed such that the necessary cooling is provided A minimum separation of gt 75mm to neighbouring equipment or assemblies in the area of the ventilation openings is to be maintained The installation is always to be made such that sufficient air circulation through the unit can be ensured All fastening points are always to be used to fix the unit During installation the unit is to be covered in the case that swarf from drilling can fall on or in the unit Risk of short circuit 3 Subject to technical change Adresse Gesch ftsf hrer Helmholtzstrasse 13 Tel 49 0 781 206 0 Karl Schneider Dipl Ing FH VaN D 77652 Offenburg Fax
17. ns switch on By means of this test it is possible to identify an open circuit or the high resistivity of the battery circuit A defective battery circuit is indicated by the simultaneous illumination of the Fehler Fault and Netzbetrieb Mains Operation LEDs centralised fault indication 7 2 Battery Test During mains operation a cyclic battery test loads the battery whilst the voltage is measured In this way it is possible to evaluate the quality of the battery A seriously aged battery is indicated by the simultaneous illumination of the Fehler Fault and Netzbetrieb Mains Operation LEDs centralised fault indication The battery test is used to detect seriously aged batteries To evaluate the backup capacity of the batteries with this system it is imperative that a manual battery check is performed from time to time See Section 11 7 3 Boost Charging In exceptional cases it may be required to boost charge lead batteries Duri ng this process the final charging voltage and thus also the output voltage is increased from 26 4V to 28 6V Boost charging is activated by applying a 24V DC control voltage to connection 4 on the IO 1 terminal strip and remains activated until the control voltage is removed again Boost charging results in the operation of the batteries in the gassing area and can be used to reactivate deep discharged or sulphated batteries The boost discharge mode should only be used on open
18. ype of Connector clamp 10mm Secondary Tightening torque 1 2 1 5Nm Ua Batt Type of Connector Interface 1O 1 10 3 Type of Connector Current Share Bus CS 91 5 typ Combicon screw terminal 1 5mm Tightening torque 0 22 0 25Nm clamp 10mm Tightening torque 0 5 0 6Nm Red LED LED illuminates on e Battery operation Netzbetrieb Mains Operation LED goes out in this case U4 fault e Battery circuit open or high resistance test interval 60s e Battery weak e Battery poles reversed e Battery over temperature only in conjunction with temperature compensation Fehler Fault Subject to technical change Gesch ftsf hrer Karl Schneider Dipl Ing FH Bettina Schneider Dipl Betriebswirt BA Rolf Anti Dipl Wirt Ing FH Amtsgericht Offenburg HRB 758 J Schneider Elektrotechnik GmbH P33G1D02 050202 doc 3 3 Operation Connection IO 2 External display and control panel for the display of operating parameters and for setting option interface the device parameters option 3 4 Signal Inputs and Outputs Netzbetrieb Mains Operation Floating relay contact normally open max contact load 30V DC 0 5A Fehler Fault Floating relay contact changeover max contact load 30V DC 0 5A Floating relay contact normally open max contact load 30 V DC 0 5A Floating relay contact normally open max contact load 30 V DC 0 5A Shut Down Shut dow
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