Nextys DCW20 Manuale utente

DCW20 User Manual rev. 5

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DCW20

960W COMBO DC UPS / DC-DC

Converter

User Manual

POWERMASTER

DCW20_040-02-700-005-EH-1117

DCW20 User Manual rev. 5

Page 2/34

DISCLAIMER

NEXTYS

reserves the right to make changes without further notice to any products herein.

NEXTYS

makes no warranty, representation or guarantee regarding the suitability of its products for any

particular purpose, nor does

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assume any liability arising out of the application or use of any

product, and specifically disclaims any and all liability, including without limitation consequential or

incidental damages. “Typical" parameters which may be provided in

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data sheets and/or

specifications can and do vary in different applications and actual performance may vary overtime. All

operating parameters, including “Typicals", must be validated for each customer application by

customer's technical experts.

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does not convey any license under its patent rights nor the

rights of others.

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products are not designed, intended, or authorized for use as components in

systems intended for surgical implant into the body, or other applications intended to support or

sustain life, or for any other application in which the failure of the

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product could create a

situation where personal injury or death may occur. Should Buyer purchase or use

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products

for any such unintended or unauthorized application, Buyer shall indemnity and hold

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and its

officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs,

damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim

of personal injury or death associated with such unintended or unauthorized use, even if such claim

alleges that

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was negligent regarding the design or manufacture of the part.

The Customer should ensure that it has the most up to date version of the document by contacting its

local

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office. This document supersedes any earlier documentation relating to the products

referred to herein. The information contained in this document is current at the date of publication. It

may subsequently be updated, revised or withdrawn.

The Customer should ensure that

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product uses the most up to date Software and Firmware

provided on

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website to ensure reliable operation of the system.

All Trade Marks recognized. Specifications and information herein are Subject to change without

notice.

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DCW20 User Manual rev. 5

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1Product description...........................................................................................................................................5

2Features and benefits.......................................................................................................................................6

3Functional description ......................................................................................................................................6

3.1 UPS mode ..................................................................................................................................................7

3.1.1 Backup .................................................................................................................................................8

3.1.2 Battery health monitor..........................................................................................................................8

3.1.3 Battery charger.....................................................................................................................................9

3.1.4 Coulomb counter................................................................................................................................10

3.1.5 PC shutdown and automatic restart...................................................................................................11

3.1.6 Cold start............................................................................................................................................12

3.2 DC/DC mode ............................................................................................................................................12

3.2.1 Parallel operation ...............................................................................................................................13

3.3 Current limit ..............................................................................................................................................14

3.3.1 Current limit in UPS mode..................................................................................................................14

3.3.2 Current limit in DC/DC mode..............................................................................................................14

3.4 Inhibit ........................................................................................................................................................14

3.5 Modbus.....................................................................................................................................................15

4User interface.................................................................................................................................................19

4.1 Status........................................................................................................................................................20

4.2 Settings.....................................................................................................................................................20

4.2.1 Modbus address.................................................................................................................................21

4.2.2 Modbus baudrate ...............................................................................................................................21

4.2.3 Modbus parity.....................................................................................................................................21

4.2.4 Modbus stop bits................................................................................................................................21

4.2.5 Battery type........................................................................................................................................21

4.2.6 Battery charge voltage.......................................................................................................................21

4.2.7 Battery charge current........................................................................................................................21

4.2.8 Battery float voltage ...........................................................................................................................22

4.2.9 Battery low voltage.............................................................................................................................22

4.2.10 Battery deep discharge voltage ......................................................................................................22

4.2.11 Battery max. discharge current.......................................................................................................22

4.2.12 Battery capacity - Supercap capacitance .......................................................................................22

4.2.13 Battery min. temperature ................................................................................................................22

4.2.14 Battery max. temperature ...............................................................................................................22

4.2.15 Battery lifetime................................................................................................................................23

4.2.16 Ri alarm mode.................................................................................................................................23

4.2.17 Ri nom.............................................................................................................................................23

4.2.18 Ri max. variation.............................................................................................................................23

4.2.19 Operating mode..............................................................................................................................23

4.2.20 Nominal output voltage...................................................................................................................23

4.2.21 Max. input current ...........................................................................................................................24

4.2.22 Max. output current.........................................................................................................................24

4.2.23 Max. Backup time enable ...............................................................................................................24

4.2.24 Max. backup time............................................................................................................................24

4.2.25 Buzzer enable.................................................................................................................................24

4.2.26 Relay 1 configuration......................................................................................................................25

4.2.27 Relay 2 configuration......................................................................................................................25

4.2.28 Inhibit polarity..................................................................................................................................25

4.2.29 DC/DC output mode........................................................................................................................25

4.2.1 Output enable.....................................................................................................................................25

4.2.1 Aux enable .........................................................................................................................................26

4.2.2 PC shutdown enable..........................................................................................................................26

4.2.3 PC automatic restart enable...............................................................................................................26

4.2.4 PC shutdown delay............................................................................................................................26

4.2.5 PC shutdown time..............................................................................................................................26

4.2.6 PC restart minimum time....................................................................................................................26

4.2.7 PC off detection current threshold .....................................................................................................26

4.2.8 PC off detection timer.........................................................................................................................27

4.2.9 Battery installation date......................................................................................................................27

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4.2.10 Battery charge cycles......................................................................................................................27

4.3 Info............................................................................................................................................................27

4.3.1 Firmware version................................................................................................................................27

4.3.2 Firmware subversion..........................................................................................................................27

4.3.3 Build date ...........................................................................................................................................27

4.3.4 Build time............................................................................................................................................27

4.3.5 Serial number.....................................................................................................................................28

4.3.6 Boot cycles.........................................................................................................................................28

4.3.7 Operating time....................................................................................................................................28

4.3.8 Battery operating time........................................................................................................................28

4.4 Logs..........................................................................................................................................................29

4.4.1 Info .....................................................................................................................................................29

4.4.2 Alarms................................................................................................................................................30

4.4.3 Events ................................................................................................................................................34

4.5 Wizard.......................................................................................................................................................34

5Technical Specifications.................................................................................................................................34

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1 Product description

Use latest device Documentation, Software and Firmware to ensure reliable operation of

the system (downloadable from www.nextys.com).

DCW20 is a microprocessor controlled unit that can perform 2 functions:

1. UPS rated 960W/20A usable in any system rated 12…48Vdc

2. DC/DC converter (non isolated) rated 960W/20A usable in any combination of IN/OUT

voltages 12…48Vdc

For the UPS function, it may use 1 battery of 12V, independently of the operating load voltage. For

any supply voltages (12…48Vdc) it may use also multiple battery configuration (10…58Vdc). DCW20

monitors the voltage coming from a DC power supply and in case of power failure a backup battery is

supplying the energy to the load. In normal condition the battery is kept charged by an integrated

battery charger supporting various battery chemistries.

As a DC/DC converter (no battery present) the input must be connected to the battery connector.

The input voltage is converted to any output voltage as per the set-up.

1. Alarm LED indicator: ON when the unit is in

backup. Blinks at 1Hz rate in case of error.

2. Modbus over USB: Used to connect a PC

running POWERMASTER or custom application

for remote monitoring and controlling. Firmware

update is also possible through USB

connection.

3. Temperature sensor: Optional temperature

sensor (P/N: WNTC-2MT) to measure the

battery temperature for protection and

temperature compensated charge method.

4. Relays dry contacts: 2 relays are present for

remote monitoring. See §4.2.26 for more

details.

5. Modbus over RS485: Used to connect a PC

running POWERMASTER or custom application

for remote monitoring and controlling. Firmware

update is also possible through RS485

connection.

6. Inhibit input: A voltage between 5VDC and

30VDC applied to this input activates the inhibit

function (§3.4).

7. Auxiliary output supply: Maximum 5A supply

from the battery (unregulated).

8. Input connection: 2 poles are provided for input connection. This must be connected to a

power supply rated 12…48VDC.

9. Output connection: 2 poles are provided for output connection. It must be connected to the

load to be backed up.

10.Battery connection: 2 poles are provided for battery connection. This must be connected to

the battery. Although the unit is protected, please respect the correct polarity.

11.Display area: provides information regarding the device status.

12.Control keys: 4 push buttons are provided to navigate through the menus and to select the

various functions.

Figure 1: Front panel view

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2 Features and benefits

The main features are:

Integrated battery charger for 12…48V multi-chemistries batteries with a charging current up

to 20A

Can be operated with SUPERCAP capacitors instead of batteries

20 A or 960W rated load

Automatic sensing of input voltage, load current and battery current

Battery protection against reverse polarity connection and overcurrent

Battery health monitoring system: measuring battery resistance, battery temperature,

charge/discharge cycles and Coulomb counter

User settable maximum backup time

Remote inhibit input

Connection for a battery thermal sensor (optional)

Modbus over USB and RS-485 interfaces for control and monitoring

Auxiliary output from the battery voltage (max. 5A), protected against overcurrent/short circuit

Suitable for energy management applications

Suitable for POWERMASTER software (available for Windows and Android)

Embedded user interface:

4 keys and 1 color graphic LCD display

Allows online device configuration

Displays the DCW20 status and alarms

2 Dry contacts for programmable status signals

Free PC and Android application POWERMASTER used for:

Connection through Modbus

Remote monitoring and configuration

Firmware upgrade

Same functionalities of the embedded user interface with the ease of the PC benefits

3 Functional description

DCW20 is a high performance digitally controller DC-UPS that can be used in any DC system with a

rated voltage between 12V and 48V and up to 20A.

At the core of the device a bidirectional DC/DC buck-boost converter (see Figure 2) acts as a battery

charger when the input supply is present. In case of a power outage (backup) the converter keeps the

output voltage regulated draining power from the battery. The converter is digitally controlled.

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Input Input

switch

Input voltage

and current

measurement

Output voltage

and current

measurement

Output

Battery voltage

and current

measurement

Auxiliary voltage

and current

measurement

Auxiliary

supply

Battery 30A

Fuse

DCDC

Bidirectional

digital control

DC/DC

converter

Battery

reverse

polarity

protection

Digital

fuse

uController

Power path

Monitoring and control

Battery health

monitor Modbus/RTU USB

RS485

I/O 2xRelays

Inhibit

HMI

Figure 2: DCW20 simplified block diagram

3.1 UPS mode

In UPS mode the DCW20 protects a

load from unwanted power interruption

in case of mains failure. An example of

UPS connection is given on Figure 3.

When the input is present DCW20 acts

as a bypass, connecting the input to the

output via the input switch. Meanwhile, if

required, the battery is charged. During

bypass there is no voltage conversion,

therefore the output supply voltage is

equal to the input voltage.

In case of power outage, the DCW20

takes energy from the battery to keep

the output regulated at “Nominal output

voltage” (§4.2.20).

Figure 3: UPS connection example

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3.1.1 Backup

The system is in backup mode if the supply for the output is sourced from the battery (input supply

missing). During backup the battery is monitored continuously to prevent over discharge.

A programmable backup timer (§4.2.24) is also implemented in order to fix a maximum backup time

during power outages. This allows preserving the battery life and shortening the recharge time,

avoiding discharging the battery when not needed.

During backup the internal Coulomb counter is used to give an estimation of the residual charge of

the battery.

Backup starts when the output voltage is lower than 90% of the “Nominal output voltage”(§4.2.20).

3.1.2 Battery health monitor

The battery health monitor is composed of:

Internal resistance measurement: The resistance is periodically measured. The internal

resistance is a good indicator of the battery health status; a sudden increase of the internal

resistance indicates a potential problem on the battery or on the battery wiring.

Temperature measurement: The battery temperature is monitored through an optional

temperature sensor (P/N: WNTC-2MT). The battery charger takes into account the battery

temperature and provides a temperature compensated charging voltage. In case of over or

under temperature the system disconnects the battery to prevent damage.

Coulomb counter: Estimates the remaining battery capacity and consequently the

available backup time.

Deep discharge protection: It protects against the deep discharge of the battery which

can lead to its irreversible damage.

The battery internal resistance (Ri) is measured by draining a defined AC current through an active

load (AL) from the battery and measuring the AC voltage drop across the load terminals. The principle

is represented in Figure 4.

AC active

load (AL)

Battery

Ri+

Rcables Iac

Rcon

Uac

Figure 4: Internal resistance measurement

The measured resistance is the sum of the battery internal resistance, the cables resistance and the

connectors resistance, therefore cabling problem such as loose connectors are also detected with Ri

measurement.

When high capacity batteries and/or small and long cables are used Rcables+Rcon may be > Ri.

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3.1.3 Battery charger

The battery charger supports various chemistries such Lead-Acid, Nickel, Lithium and

Supercapacitors. The charging algorithm for each chemistry is given below. Other charging algorithms

can be implemented by request (contact factory).

The battery charger automatically reduces the current to avoid exceeding the maximum input current

(§4.2.21) in case of high current load.

The user must set the following parameters to allow the charger to perform correctly:

Battery type (§4.2.5).

Battery charge voltage (§4.2.6)

Battery charge current (§4.2.7)

Battery float voltage (§4.2.8)

The battery charge terminates in case at least one of the following conditions are satisfied:

Low current: The measured battery charge current is lower than 10% of the “Battery

charge current”while the measured voltage is at least 98% of the “Battery charge voltage”.

Timer: the charge is terminated after the battery has been charged for a predetermined

amount of time. The value is automatically calculated by the device.

For Nickel batteries only, the following conditions are also checked:

Temperature Cutoff (TCO): The battery temperature if higher than the “Battery maximal

temperature” (§4.2.14) minus 3°C for more than one minute. For example, if the maximal

battery temperature is set to 60°C, the charge terminates in case the temperature is higher

than 57°C.

Rate of Temperature Increase (ΔT/dt): The battery temperature is rising at a rate equal or

superior to 1°C/min. To avoid unattended end of charge do not place the system on an

ambient with rapid changes of temperature (for example exposed to direct sunlight).

The charger voltage is independent on the input voltage (power supply), and is user settable.

Lead acid and lithium batteries share the same 3 stages charging algorithm as shown on Figure 5.

Time

Current

Voltage

Constant current Constant voltage Maintenance

Charge current

Charge voltage

Float voltage

Figure 5: Lead acid and Lithium charging algorithm

For nickel batteries, during maintenance, the DCW20 gives pulses of 3s every 30s with a maximum

current of 1/10 of “Battery charge current” and maximum voltage equal to “Battery charge voltage”.

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Time

Current

Voltage

Constant current Constant voltage Maintenance

Charge current

Charge voltage

Figure 6: Nickel charging algorithm

For Supercapacitor after the constant current phase the algorithm goes directly to maintenance

keeping the voltage at “Battery charge voltage”.

Time

Current

Voltage

Constant current Maintenance

Charge current

Charge voltage

Figure 7: Supercapacitors charging algorithm

Warning: In order to avoid potentially hazardous situations including fire hazard, safety

recommendations must be followed. Only authorized staff can install the unit.

Warning: For Lithium cells the balancing and protection circuit must be included in the

battery pack.

For Nickel batteries the use of the external temperature sensor is mandatory. The sensor

must be placed in contact with the battery.

3.1.4 Coulomb counter

DCW20 measures the current flowing from / to the battery to keep track of the capacity available on

the battery. The capacity is measured in Ampere Hour [Ah]. The value shown is based on the

following assumptions:

The value shown is just informative and does not represent the real state of charge of the

battery in some circumstances, for example if the battery is damaged.

When the battery is connected for the first time or the system starts from OFF, the system

assumes the battery is fully discharged and start with 0Ah counter.

Once the battery is fully charged the system sets the counter to the nominal capacity

specified by the user (§4.2.12).

DCW20_040-02-700-005-EH-1117

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