TDK-Lambda DUSH Series User Manual

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User Manual

DUSH Series | Uninterruptible DC Power Supplies

emea.lambda.tdk.com/dush-series

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Summary of Contents for TDK-Lambda DUSH Series

Page 1 User Manual DUSH Series | Uninterruptible DC Power Supplies emea.lambda.tdk.com/dush-series...
Page 2 Table of content Safety regulations / installation notes ....1 SETTINGS ............24 General safety instructions ........1 System alarms ............ 29 Intended use ............1 6.4.1 DUSH System Alarms ........30 Qualification of users ..........1 6.4.2 DUSH System Events......... 32 System configuration ..........
Page 3 Safety regulations / installation notes General safety instructions • Disconnect the input voltage and energy storage before installation, maintenance or service work and secure it against unintentional reconnection. • Prevent the ingress of foreign objects, such as screws or metal chips. •...
Page 4 System configuration • In order to guarantee the optimal functionality of the DUSH, it is essential to configure the system parameters through one of the following methods: PowerCMC, Modbus, or directly on the device. Otherwise, the DUSH may enter an error state. Firmware update To guarantee the safe and seamless operation of the DUSH, it is imperative to utilise the most recent version of both the PowerCMC remote HMI software and the DUSH firmware.
Page 5 Description Disclaimer TDK reserves the right to make changes without further notice to any products herein. TDK makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does TDK 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.
Page 6 Operating and connection elements Figure 1 : Operating and connection elements 1,5” color LCD Navigation keys LED indication info Temperature sensor connector Push-in terminal, pluggable Web link to product documentation (alarm relays, Modbus/RTU, inhibit, AUX) Push-in terminal, pluggable Alarm LED (alarm relays, Modbus/RTU, inhibit) Mini USB interface Push-in terminal (input, output, battery)
Page 7 Display The status screen displays the measured values and status information to facilitate system diagnostics. Furthermore, in case of alarm a message appears on the screen after 60 seconds of inactivity (no key pressed). Figure 3 : Alarm or warning Figure 2 : Menu STATUS Alarm LED LED indication...
Page 8 Main approvals IEC EN 61010-1 IEC EN 61010-2-201 IEC EN 62368-1 (Ed. 2 & Ed. 3) UL CSA 61010-1 UL CSA 61010-2-201 UL CSA 62368-1 (Ed. 3) EU Low Voltage Dir. 2014/35/EU EU EMC Dir. 2014/30/EU EU RoHS Dir. 2011/65/EU Safety and EMC Reg.
Page 9 Mounting / Dismounting Mounting Place the mounting rail holder on the upper edge of the mounting rail and push down. Push the lower part of the device toward the mounting rail until the mounting rail holder engages. The device is now mounted on the mounting ...
Page 10 Dismounting WARNING DANGER OF BURNS Depending on the ambient conditions, the housing temperature can reach very high temperatures. • Do not touch the housing of the device during operation. • Once the device has been disconnected from the power supply, do not touch the housing until it has cooled down for a few minutes.
Page 11 Mounting positions The DUSH DC-UPS can be mounted on the DIN rail in the following positions. Figure 6 : Recommended mounting position Figure 7 : Optional mounting positions NOTICE Available output power and derating values can be found in the technical specification →...
Page 12 Installation clearance / Cooling Installation clearances � Vertically (Z axis) Top side min. 40mm (1 � Bottom side installation above heat sources not min. 20mm ( permitted � Horizontally (X axis) Left side / Right side 3a 4a min. 15mm ( �...
Page 13 Connection / terminal blocks / interfaces • Use an appropriately sized power supply, which can deliver the additional required internal current consumption of the DUSH DC-UPS and the required current for charging the batteries. Use power supplies that do not deliver more than 20 A continuous output current (check max. current input). •...
Page 14 Terminal blocks 2.x (MB-RTU/AUX/R1/R2/INH) Figure 12 : DUSH960-1248-1M Figure 11 : DUSH960-1248-0M Ø [AWG] 28 … 16 Ø [mm² 0.2 … 1.0 Ø [AWG] 28 … 16 Ø [mm²] 0.2 … 1.5 Ø [mm²] 0.25 … 0.75 Ø [mm²] 0.25 … 1.0 �...
Page 15 Functional description UPS mode 5.1.1 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.
Page 16 5.1.2 Battery charger NOTICE 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. The battery charger supports various chemistries such Lead-Acid, Nickel, Lithium and Supercapacitors.
Page 17 For nickel batteries, during maintenance, the DUSH960-1248-xM gives pulses of 3 s every 30 s with a maximum current of 1/10 of “Battery charge current” and maximum voltage equal to “Battery charge voltage”. Constant voltage Constant current Maintenance Charge voltage Voltage Charge current Current...
Page 18 5.1.4 PC shutdown and automatic restart PC shutdown: In case the DUSH960-1248-xM is used to supply a PC it is possible to automatically shut down the PC after an adjustable time of backup. For this the PC must run the PowerCMC application (provided free) and must be connected through Modbus.
Page 19 Parameter Name Description PC to detect the supply ON > OFF > ON cycle to restart. PC OFF detection timer User settable ( 6.3 SETTINGS). Minimum time at which the output current must be below the Ioff current threshold to trigger the automatic PC restart (PC supply ON >...
Page 20 5.1.6 Battery Cycling When this option is enabled the device schedules and activates a periodic battery discharge on a user settable day and time of the week. The user can select after how many weeks the system repeats the cycle. The purpose of this function is to verify the battery capacity/health.
Page 21 INFO, and into the tab Status of the PowerCMC application. The battery cycle is ended when one of the thresholds, specified by “Battery cycle SoC threshold” and by “Battery cycle time threshold”, is reached. Once the programmed battery cycle process terminates the device turns back to nominal function.
Page 22 INFO under “Next battery cycle” or through Modbus field “Next battery cycle”. Below a list of the LOGS and DUSH System Events related to this function: Battery cycle active Primary value Secondary value Battery cycle ended Minimum battery voltage during the battery cycle Battery cycle started Battery voltage at start of battery cycle Battery cycle triggered by...
Page 23 loading a battery overcurrent alarm is triggered and the output voltage starts to decrease. When the battery discharge current is approaching the threshold, the measured battery current is displayed with red fonts on the LCD. 5.1.9 Shutdown and reset on request The device offers the on request reset or shutdown feature.
Page 24 Operating Menu structure Figure 20 : Menu structure 22 | 50...
Page 25 STATUS The status screen shows the measurement and statuses to ease the system diagnostic. Figure 21 : Figure 22 : UPS status screen Warning screen The screen is divided into sections, which are identified by the symbols and values shown in the following table: Display item Name...
Page 26 SETTINGS The setting menu contains all the configurable parameters available to the user. Use the UP/DOWN KEY to navigate through the menu items. Press the OK KEY to enter and exit the editing mode, exiting the edit mode stores and activates the new configuration. While in editing mode use the UP/DOWN key to change the selected value.
Page 27 Parameter Description Range/Value This value is used as threshold for the “Battery under temperature” alarm. Bat. lifetime Set the maximum battery lifetime regarding 1 … 100,000 h to the battery manufacturer (see datasheet of the battery). This value is used as threshold for the “Battery lifetime elapsed”...
Page 28 Parameter Description Range/Value It must correspond and not exceed the max. output current of the power supply unit used on the input. Backup time enable If enabled the DUSH shuts down if the Disabled, Enabled backup last more than the “Max. backup time”...
Page 29 Parameter Description Range/Value PC shutdown time Set the shutdown time for the “PC 1 … 600 s shutdown” function of the DUSH in combination with the PowerCMC software.  5.1.4 PC shutdown and automatic restart PC restart time Set the minimum off time before restart for 1 …...
Page 30 Parameter Description Range/Value In this case, increasing the detection threshold, ensures the short circuit is detected. High inrush enable Disable/Enable the usage of the DUSH on Disabled, Enabled loads with high inrush current. When enable, the unit send a higher current pulse when the output is switched on, to withstand loads with a high start-up inrush current.
Page 31 Parameter Description Range/Value Battery cycle every Defines the intervals at which the battery 1 … 52 weeks cycle function is executed in weeks.  5.1.6 Battery Cycling Battery cycle day Specifies on which day of the week the Monday, Tuesday, battery cycle should be performed.
Page 32 Normally open 1 or more enabled alarm state Relay contact status active True Open True Closed False Closed False Open 6.4.1 DUSH System Alarms Alarm LCD name Description Backup Backup Active when the system is in backup mode Battery SoC < 25% Bat.
Page 33 Alarm LCD name Description When active, the battery charger is disabled. Disconnect the battery to reset the alarm. Battery over discharge current Bat. over discharge I Active when the measured battery discharge current reaches the threshold specified in the “Battery max.
Page 34 Alarm LCD name Description temperature increases more the device may switch OFF. Error over temperature Error over temperature Active when the internal temperature is too high. To prevent damage the device switches OFF. Output short circuit Output short circuit Active when a short circuit is detected on the output.
Page 35 INFO While in the info menu, use the UP/DOWN KEY to navigate through the menu items. The fields are also accessible via Modbus at the specified address. Modbus device identification fields are read using function 43/13 (0x2B/0x0E) at the specified object id. Parameter Description Value...
Page 36 LOGS Figure 23 : Menu LOGS Value1: optional, see tables below for Time: time at which the log occurred details Value2: optional, see tables below for Date: date at which the log occurred details LCD Name: unique log name Logs are of 3 different kinds: info, alarms and events. All info and alarms have an associated Modbus field representing the current status (0 if inactive or 1 if active).
Page 37 LCD Name Description Value 1 Value 2 PC shutdown PC shutdown: 0 – inactive Not used Command to shutdowns 1 – active the PC. PC power OFF PC power off: 0 – inactive Not used Command to power OFF 1 – active the PC, DUSH960-1248-xM output switches OFF.
Page 38 LCD Name Description Value 1 Value 2 measured temperature Status 1  0: (using the optional Max. measured value external sensor) is under the threshold specified in “Battery max. temperature” field. If active the battery charged is disabled. Bat. lifetime elapsed Battery lifetime elapsed: 0 –...
Page 39 LCD Name Description Value 1 Value 2 Input under voltage Input under voltage: 0 – inactive Status 0  1: Active when the 1 – active Offending threshold measured input voltage is Status 1  0: under 90 % of the Min.
Page 40 LCD Name Description Value 1 Value 2 is in backup and the maximal backup time is less than the “Max. backup time” filed Warn. over temperature Warning over 0 – inactive Not used temperature: 1 – active Active when the internal temperature is high.
Page 41 LCD Name Description Value 1 Value 2 cause/reason of battery 3 – Input UV cycle ending 4 – Battery in charge 5 – User • State of charge: Battery cycle ended at specified state of charge • Time limit: Battery cycle ended after specified time •...
Page 42 SPECIFICATION. Documents available on http://www.modbus.org/. Remote HMI The TDK-Lambda control and monitoring center "PowerCMC" offers a comfortable remote maintenance and control of the DUSH DIN-Rail UPS system. All values and parameters can be set and/or adjusted. Comprehensive save and recall options of the system settings and parameters make the maintenance workflow easy.
Page 43 Operating and basic functions System overview Figure 24 : System overview 41 | 50...
Page 44 Input-Output path Figure 25 : Input-Output path The Input to Output path of the DUSH is not regulated and has a nominal range of 12V … 48V (max. … 60V ). There is no protection on the Input – Output path hence a fitting power supply must be used at the input of the DUSH.
Page 45 Auxiliary output Figure 27 : Auxiliary output The auxiliary output of the DUSH is powered from the battery with no regulation. The auxiliary voltage follows the battery voltage in a range of 12V … 48V with a maximum current of 5A. A digital fuse protects the auxiliary output.
Page 46 Typical wiring diagram Figure 28 : Power connection Figure 29 : I/O connection 44 | 50...
Page 47 Energy storage technologies Buffer technologies 9.1.1 Lead acid / Lead gel 9.1.1.1 Advantages • • Maintenance free; can be mounted sideways; low self-discharge • • Performance stays high until the end of life, then drops rapidly • • Dependable and inexpensive on a cost-per-watt base 9.1.1.2 Limitations •...
Page 48 9.1.4 Supercapacitors 9.1.4.1 Advantages • Virtually unlimited cycle life • High specific power; low resistance enables high load currents • Charges in seconds; no end-of-charge termination required 9.1.4.2 Limitations • Low specific energy; holds a fraction of a regular battery •...
Page 49 Deep discharge To ensure the service life and safety of the battery, deep discharges should be avoided. A deep discharge occurs when the voltage falls below a certain value. The deep discharge voltage is specified by the battery manufacturer. The consequences of a deep discharge can permanently damage the battery depending on the battery type and usage.
Page 50 Battery temperature compensation The chemistry in lead-acid batteries causes energy to flow more easily in warm temperatures and less easily in cold temperatures. This affects how much energy a battery can absorb during the recharge process. Most charger voltage setpoints are set for room temperature 25°C (77°F). If that setpoint is not adjusted for temperature, the battery might get overcharged and gas when it’s too warm, or undercharge and sulfate when it’s too cold.
Page 51 Technical data NOTICE The complete technical data can be found in the technical specification → https://www.emea.lambda.tdk.com/dush-series. 49 | 50...
Page 52 UM000021A01_DUSH_User_Manual.docx...

This manual is also suitable for:

Dush960-1248-0m Dush960-1248-1m