UM000005 DCW20 User Manual
UM000005 DCW20 User Manual
UM000005 DCW20 User Manual
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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.
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.
The device is able to monitor the internal hardware in order to detect failures and/or malfunctions and
alerts the user through both, the log system (§4.4) and own display.
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.
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.
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.
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”.
For Supercapacitor after the constant current phase the algorithm goes directly to maintenance
keeping the voltage at “Battery charge voltage”.
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.
The diagram below shows the DCW20 behavior when Shutdown and automatic restart is enabled.
Input voltage
E1
Output voltage
PC status
PC OFF signal E4
The parameters are settable through the DCW20 user interface or using the POWERMASTER
application. The checkbox “Run on startup” must be checked on POWERMASTER when PC shutdown
function is used. To inhibit the software from calling the shutdown command user can select the
“Inhibit shutdown” check box.
From front panel: Press and hold simultaneously the and buttons until you see the
welcome message on the screen.
Remotely through inhibit input: When enabled on the user settings (§4.2.32), the device
cold starts toggling the inhibit status from true to false.
On battery connection: When enabled on the user settings (§4.2.33), the device
automatically cold starts when the battery, previously disconnected, is connected to the
device.
Please, take in account that the battery connection can take up to 5 seconds to be detected and the
inhibit state can take up to 3 seconds to be changed when in low power mode.
Into the device’s SETTINGS menu the parameters “Battery cycle hour” (§4.2.56) and the “Battery
cycle minute” (§4.2.57) are grouped into the “Battery cycle time” field.
Any time one of those parameters is modified or a start up is performed the battery cycle sheduling is
recalculated.
The process is scheduled at time specified by “Battery cycle hour” (§4.2.56) and “Battery cycle
minute” (§4.2.57) parameters at the first available day specified by “Battery cycle day” (§4.2.55)
parameter.
Once the scheduled day and time are reached the battery cycle starts and the next event is
scheduled at the same day, at the same time but after the number of weeks specified by “Battery
cycle every” (§4.2.54) parameter.
When the battery cycle is in progress into the device’s STATUS menu, at the top, the “Scheduled bat.
disc.” message is shown. The battery cycle in progress message is shown into the field “Next battery
cycle” of the device’s INFO menu, and into the tab Status of the POWERMASTER application.
The battery cycle is ended when one of the thresholds, specified by “Battery cycle SoC threshold“
(§4.2.58) and by “Battery cycle time threshold” (§4.2.59), is reached. Once the programmed battery
cycle process terminates the device turns back to nominal function.
If the scheduled battery cycle should start while the battery is charging, the battery cycle is skipped in
order to permit to the battery a full recharge.
In case that the battery cycle is in progress and the input under voltage state is detected the battery
cycle is immediately interrupted for preserve the battery charge in case of issues on the line.
If there is a need to interrupt an ongoing battery cycle process there are three methods.
The second method is disabilng the battery cycle function through the Modbus field “Battery cycle”
(§4.2.53) setting field as “Disabled”.
The third method is stopping the current battery cycle through the Modbus field “Battery cycle stop”.
User can manually start the cycle using the Modbus field Battery cycle start, this will not affect the
automatic scheduling. When starting manually, the cycle starts regardless of the battery status (e.g.
battery charging).
The information about the next battery cycle is shown in the device’s INFO menu under “Next battery
cycle” or through Modbus field “Next battery cycle” (§4.3.9).
Parallel connection for power increase of multiple DCW20 units is not recommended in
UPS mode. Contact factory for details.
Maximum input current (§4.2.21), default 20A: it is used to limit the input current at a
specified threshold. For example, if the DC power supply is rated less than 20A the threshold
can be lowered to avoid too high current drain from the power supply. When the input current
limit is reached, the battery charging current is limited; if the input current cannot be kept below
the threshold due to excessive loading an input overcurrent alarm is triggered. When the input
current is approaching the threshold, the measured input current is displayed with red fonts on
the LCD.
Battery maximum charge current (§4.2.7), default 0.5A (maximum settable 20A): it is used to
limit the maximum charge current supplied to the battery. This threshold will be automatically
reduced in such manner that the maximum input current limit (§4.2.21) is distributed to the load
with priority towards the charging.
For example, if the maximum input current limit is 20A and the load needs 10A while the
maximum charge current is set at 12A, the controller will limit the charging current automatically
to 10A until the load will need <10A.
Battery maximum discharge current (§4.2.11), default 20A: it is used to limit the maximum
discharge current delivered from the battery during the backup function. When the threshold is
reached due to excessive 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.
Maximum input current (§4.2.21), default 20A: it is used to limit the input current at a
specified threshold. For example, if the DC power supply is rated less than 20A the threshold
can be lowered to avoid too high current drain from the power supply. When the input current
limit is reached due to excessive loading an input overcurrent alarm is triggered. When the
input current is approaching the threshold, the measured input current is displayed with red
fonts on the LCD.
Maximum output current (§4.2.22), default 20A: it is used to limit the maximum current
delivered to the load. When the threshold is reached due to excessive loading an output
overcurrent alarm is triggered and the output voltage starts to decrease. When the output
current is approaching the threshold, the measured output current is displayed with red fonts on
the LCD.
3.4 Inhibit
An opto-isolated input allows the inhibition of the backup function in UPS mode or switching off the
output on DC/DC mode. The polarity of the input can be defined using the “Inhibit polarity” field
(§4.2.28).
The first mode starts the shutdown/reset sequence immediately after a “Shutdown” or “Reset device”
Modbus command (see §3.6 “Commands” section) is received by the DCW20.
The second mode starts the shutdown/reset sequence with a delay specified through Modbus fields
“Delayed device shutdown time” (§4.2.50) and “Delayed device reset time” (§4.2.51).
3.6 Modbus
DCW20 communicates through Modbus/RTU as specified on “MODBUS over Serial Line” and
“MODBUS APPLICATION PROTOCOL SPECIFICATION” documents available on
http://www.modbus.org/.
Table 2 contains the field types and Table 3 the mapped fields. For types bigger then 16bit, access all
registers in one transaction (multiple register read or write) to ensure atomic operation.
Status:
This is the default view where the user can find the
most relevant information about the device status.
The system always falls back to this view after 60s of
inactivity (no key pressed).
Settings:
All the device settings are configurable from this
menu. Use the UP/DOWN KEY to navigate through
the parameters. Press the OK KEY to enter/exit the
editing mode. In editing mode use the UP/DOWN
KEY to change the highlighted value.
Info:
Device information such as firmware version, serial
number and device name is visible from this menu.
Logs:
All the alarms and event are logged in a circular
buffer and visible from this screen. Use the
UP/DOWN KEY to navigate through the logs.
Wizard:
The wizard helps the user to configure the system
through a series of screens.
4.1 Status
The status screen shows the measurement and statuses to ease the system diagnostic. The screen is
divided in sections identified by the symbols shown below:
Input: The measured input voltage and current is shown in this section.
Output: The measured output voltage and current is shown in this section.
Battery: The battery voltage, current, temperature, resistance and charge are shown in this
section. During charging and discharging the symbol background color changes to orange and
the number of bars drawn inside reflects the charge status. During discharging and charging
an arrow drawn beside the symbol reflects the direction of the current flowing through the
battery, pointing towards the battery during charging. Battery section is not present in DC/DC
mode.
Auxiliary: The measured auxiliary output voltage and current is shown in this section.
For each section the icon background color reflects its status, green on healthy state or red/orange
otherwise.
Furthermore, in case of alarm a message appears on the screen after 60s of inactivity (no key
pressed).
Figure 11: UPS status screen Figure 12: DC/DC status screen Figure 13: Alarm screen
4.2 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
4.2.17 Ri nom.
Default value Range Resolution
1mΩ 1…300mΩ 0.1mΩ
Unit LCD name Modbus address
Milli ohm Ri nominal 0x101C
Used for the threshold calculation of the “Battery Ri too high” alarm (§4.4.2.2).
4.3 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.
4.4.1 Info
4.4.1.1 Battery charging
LCD name Modbus address
Bat charging 0x4000
Value1 Value2
Inactive (0), Active (1) Not used
Active when the battery is charging.
4.4.1.7 PC shutdown
LCD name Modbus address
PC shutdown 0x4022
Value1 Value2
Inactive (0), Active (1) Not used
Command to shutdowns the PC (see §3.1.5).
4.4.1.10 Inhibit
LCD name Modbus address
Inhibit 0x4025
Value1 Value2
Inactive (0), Active (1) Not used
Active if the inhibit input signal is asserted (see §3.4).
4.4.2.11 Backup
LCD name Modbus address
Backup 0x4030
Value1 Value2
Inactive (0), Active (1) Not used
Active when the system is in backup (§3.1.1).
4.4.3 Events
4.4.3.1 Power ON event
LCD name Modbus address
Power ON 0xE000
Value1 Value2
Power ON count Not used
Generated at every time the DCW20 is turned ON.
4.5 Wizard
The wizard assists the user during the DCW20 configuration. It should be run once at commissioning.
5 Technical Specifications
See DCW20 datasheet available on www.nextys.com.
6 Installation procedure
See DCW20 short form installation manual, available on www.nextys.com, for information related to
installation procedure.