Battery Controller Module TSP-BCMU360 Series, 360 Watt CB Scheme EMC Features UL 60950-1 IEC 60950-1 ◆ Universal battery controller module for uninterruptable 24 VDC and 48 VDC bus voltage ◆ Redundant inputs for two indepedant sources ◆ Battery protection for over voltage, deep discharge, short circuit and reverse connection ◆ Alarm outputs for input, output and battery condition This module provides a professional battery management system to charge and ◆ Remote On/Off for battery monitor an external 12V lead-acid battery. Together with a power supply of the ◆ Controlled end of charge voltage by TSP series or any other stabilized 24 VDC or 48 VDC power supply a perfect DC- temperature sensor UPS system can be configured. The connected battery will be charged and held ◆ International safety approval package in charged mode by the power supply. In the event of a mains power failure the battery will supply the output power until the battery is discharged. A step up con- ◆ 3-year product warranty verter is used to maintain the selected output voltage level, Vnom - 6% (typical). To avoid overcharging the battery, an external temperature sensor adjusts the battery voltage automatically to the required end of charge voltage. This can extend the battery life. The battery is protected against deep discharge. Mains power and bat- tery status are monitored regularly and failures indicated by corresponding LED’s and alarm outputs. The module also provides an external On/Off input to switch-off TSP-TS battery temperature sensor (10 kOhm NTC with 2m cable) optional both, power supply and battery. Models Output Current Output Power Order code Inputs Input voltag range Back up battery max.* max. 12V lead acid battery 2 x 360 W, for any single 24–28 or 48–56 VDC 24 VDC / 15 A (to purchase on local TSP-BCMU360 or two identical 24 VDC or (range selection with 360 W 48 VDC / 7.5A market, or TRACO 48 VDC sources jumper) POWER battery pack) * Maximum current at nominal Vout Accessory: TRACO POWER 12V battery pack: TSP-BAT12-072 Datasheet: www.tracopower.com/products/tsp-panas_072.pdf http://www.tracopower.com Page 1 of 8 Battery Controller Module TSP-BCMU360 Series 360 Watt Output Specifications Output voltage / current – Normal Mode 24 VDC mode: Vin – (0.4 - 0.8V); 15 A max. 48 VDC mode: Vin – (0.4 - 0.7V); 7.5 A max. – Buffer Mode 24 VDC mode: 22.2 – 22.9 VDC; 10 A (15 A in boost mode for 10min) 48 VDC mode: 44.6 – 45.3 VDC; 5 A (7.5 A in boost mode for 3min) Efficiency – Normal mode 94 – 98 % (battery charged) (load >50 % of Iout max.) – Buffer mode 87 – 92 % General Specifications Operating temperature – Normal Mode –25°C to +70°C max. (without derating) – Buffer Mode nominal 24 VDC mode: derating above +50°C : 2.0 %/K 48 VDC mode: derating above +40°C : 2.0 %/K – Buffer Mode boost 24 VDC mode: up to +40°C for 10 minutes max. 48 VDC mode: up to +40°C for 3 minutes max. Storage temperature –25°C to +85°C max. Temperature coefficient 0.02 %/K Humidity (non condensing) 95 % rel. H max. Reliability, calculated MTBF at +25°C acc. to IEC 61709 > 1.5 Mio. h Battery protection against over voltage, deep discharge, overcharge, short circuit and reverse connection (built-in fuse) Signals – Status DC OK input, DC OK output, BAT OK all relay contact closed and LED on at status OK – Contact rating 30 VDC / 1.0 A max. 60 VDC / 0.5 A max. Battery charging current 0.8 – 1.2 A Nominal battery voltage (at 25ºC) 13.6 VDC (factory setting) Battery voltage adjustment range 13.2 – 14.4 VDC Battery restistance test 100mOhm min. (normal mode at 25ºC) Battery test current 2.5A / 60ms typ. (normal mode at 25ºC) Battery test interval (acc. to jumper setting) 15s or 10min Battery warning 10.4 – 11.4 VDC (buffer mode only) Battery disconnection 9.1 – 9.7 VDC (buffer mode only) Battery remote Off disconnects battery in buffer mode (see page 6 - connector) Automatic battery temperature compensation range –15ºC – 50ºC Degree of protection IP 20 (IEC/EN 60529) Altitude during operation 2000 m Safety standard IEC/EN 60950-1, UL 60950-1 (2nd) + Am1:2011 UL508 – requirements Safety approvals – CSA ( UL60950, UL508) www.tracopower.com/products/tsp-modules-csa.pdf – CB test certificate IEC 60950-1 (SIQ for EN) www.tracopower.com/products/tsp-bcmu-cb.pdf Electromagnetic compatibility in correspondence to connected unit (no internal switching device) Environment – Vibration acc. IEC 60068-2-6; 3 axis, sine sweep, 10 – 55 Hz, 1 g, 1 oct/min – Shock acc. IEC 60068-2-27 3 axis, 15 g half sine, 11 ms Enclosure material aluminium (chassis) / stainless steel (cover) Mounting – DIN-rail mounting for DIN-rails as per EN 50022-35x15/7.5 (snap-on with self-locking spring) – Wall mounting (option) with wall mounting bracket - see page 7 Connection – Input Output battery screw terminal (plug included) – Signal & control detachable screw terminals (plugs included) Installation instructions www.tracopower.com/products/tsp-bcmu360-inst.pdf All specifications valid at nominal input voltage, full load and +25°C after warm-up time unless otherwise stated. http://www.tracopower.com Page 2 of 8 Battery Controller Module TSP-BCMU360 Series 360 Watt Function Specification Function Diagram: 1. General Description The TSP-BCMU360 module extends any 24VDC or 48VDC power supply to a DC-USV (uninterruptable DC Power supply). This module is a standalone unit and is designed to function with the Traco TSP series; however it can be used in conjunction with any fully stabi- lized 24V or 48V DC power supply output. The set voltage is configured through the means of a jumper on the unit with two selecta- ble DC voltage levels, 24V or 48V. No other signals are required between the TSP-BCMU360 and the connected power supplies for correct operation of the module. In the event of power fail from the connected power supply, the energy required by the load will be supplied continuously and without interruption from an external 12V lead acid battery. The module also offers the unique feature of redundant inputs as well as the battery backup. Redundancy is achieved by two internal decoupling diodes which allow operation with two independent voltage sources in order to increase the reliability of the output even further. 2. Operation 2.1. Battery Backup for USV Operation The TSP-BCMU360 module extends any 24VDC or 48VDC power supply to a DC-USV (uninterruptable DC Power supply), this is achie- ved by the connecting a 12V lead-acid battery to the BATT_IN connector of the unit. During normal operation, the connected power supply provides energy to load with a voltage level of Vin –0.5V (typical, 0.5V loss due to internal decoupling diodes) as well as char- ging the connected battery. If the connected supply fails, the battery is then connected to the load (buffer mode), a step up converter is used to maintain the selected output voltage level, Vnom - 6% (typical). 2.2. Dual Inputs for Redundancy The module provides two inputs to connect two power supplies to facilitate a redundant system. If one of the two connected sources fails then the second supply will provide energy to load maintaining the desired operation of the unit. The unit is designed to function with the TRACO POWER TSP series, but due to its standalone nature it can be used with any type of fully stabilized 24V or 48V power supply. 2.3. Output Voltage Level and Efficiency The TSP-BCMU360 module functions with both 24VDC (15A) and 48VDC (7.5A) supplies. The desired voltage is selectable by means of a jumper located on the side of the unit. It also offers very high efficiencies with up to 96% and 98% efficiency in normal mode for 24V and 48V modes respectively. In the buffer mode efficiencies are as high as 92% and 89% for 24V and 48V modes respectively. http://www.tracopower.com Page 3 of 8 Battery Controller Module TSP-BCMU360 Series 360 Watt Function Specification (continued) 3. Battery When the input DC voltage is present, the TSP-BCMU360 unit will automatically charge the connected battery to a set end of battery charge voltage level, factory set for 25ºC for lead-acid batteries, using a constant current charging method of 1A (typical). As the bat- tery voltage approaches the end of battery charge voltage level, the current will decrease proportionality; this characteristic is shown in Figure 1. The user can adjust the set end of battery charge voltage level by means of the “Battery Voltage Adjust” potentiometer. 13.6V 1A Figure 1 – Battery Charge Characteristics Note: For Cycle Use (repeated charging and discharging of battery), it is recommended to use a charge current of 0.4CA or smal- ler, therefore batteries with a capacity of 2.5Ah or less should not be used with this module. The module also provides an input connector for a temperature compensation probe. If this probe is connected, the unit will automati- cally compensate the end of battery charge voltage level depending on the measured temperature. The connection of the temperature probe also negates the need to change the potentiometer to compensate for a new temperature. The battery end voltage compensation curve is shown in Figure 2. (Applicable to factory setting of 13.6V/ 25ºC) Battery End of Charge Voltage with Temperature Sensor [V] 15.0 14.8 14.6 14.4 14.2 14.0 End of Charge Voltage 13.8 13.6 13.4 13.2 13.0 -15-10 -5 05 10 15 20 25 30 35 40 45 50 [ºC] Figure 2 3.1 Battery Protection The TSP-BCMU360 module protects the connected battery against short circuit and overload by the means of a built in 40A fuse. This fuse is a standard 40A blade type fuse, which is accessible from the front panel of the unit for ease of replacement should the fuse be damaged during operation. The module also prevents deep discharge of the battery by disconnecting the battery from the load once the voltage level of battery has dropped below a defined threshold. An early warning of this disconnection is given to the user by me- ans of the BATT-OK signal (see chapter 6). The BATT-OK signal will switch off when the battery voltage is roughly 1V above the deep discharge threshold. http://www.tracopower.com Page 4 of 8 Battery Controller Module TSP-BCMU360 Series 360 Watt Function Specification (continued) 4. Ambient temperature and power rating The TSP-BCMU360 module operates at temperatures between –25ºC - 70ºC. In normal mode the module can deliver full power up to 60ºC. In Buffer mode, a current derating of 2%/ ºC is required for 24V applications above 50ºC. The boost current of 15A is available at ambient temperatures up to 40ºC for a duration of 10 minutes as shown in Figure 3. In Buffer mode, a current derating of 2%/ ºC is required for 48V applications above 40ºC. The boost current of 7.5A is available at ambient temperatures up to 40ºC for a duration of 3 minutes as shown in Figure 4 (minimum start-up temperature in buffer mode is –10ºC). Temperature Derating - Buer Mode 24V 16 15 14 max 10min. 13 12 11 10 9 8 7 6 Nominal 5 4 Boost 3 2 1 0 0102030405060 Ambient Temperature [ºC] Figure 3 Temperature Derating - Buer Mode 48V 8 7.5 7 max 3min. 6.5 6 5.5 5 4.5 4 3.5 3 Nominal 2.5 2 Boost 1.5 1 0.5 0 0102030405 060 Ambient Temperature [ºC] Figure 4 http://www.tracopower.com Page 5 of 8 Output Current [A] Output Current [A] Battery Controller Module TSP-BCMU360 Series 360 Watt Function Specification (continued) 5. Battery Remote On/Off The TSP-BCMU360 module provides a Battery Remote on/off input (2 pins on signal connector); if this input is short circuited (switch closed in Figure 5) the battery will be disconnected from the unit by means of an internal relay. A voltage of 1V or less across the Bat- tery Remote on/off terminals will disconnect the battery from the unit. If the Battery Remote On/Off signal is set to off (short between pins) this will not affect the output of the unit in normal mode, however the battery will be disconnected, hence it will not charge. If the unit enters buffer mode while the Battery Remote On/Off signal is off, the battery will remain disconnected, hence no energy will be supplied to the load. Figure 5 – Simplified Battery Remote On/Off Circuitry An overview of the Battery Remote on/off input is given in the table below. Battery State Battery Remote On/Off Pins Voltage Connected Open Circuit 5V Disconnected Short Circuit <1V 6. Signals The TSP-BCMU360 module provides three signals to the user as an indication of the status of the unit; these signals are made available as LED indicators and corresponding isolated relay contacts and are as follows. Note: All Signal Relay contacts are rated for 30VDC/1A, 60VDC/0.5A  DC-IN-OK: The DC-IN-OK LED will illuminate and relay will close if at least one of the inputs is present and has a voltage within +20 / –3% tolerance.  BATT-OK: The BATT-OK LED will illuminate and relay will close if the battery is charged and has a low internal resistance. During battery discharge operation this signal monitors the output voltage and will switch off the LED and open the relay when the battery approaches the disconnection voltage.  DC-OUT-OK: The DC-OUT-OK LED will illuminate and relay will close if the output voltage of the unit is higher than 85–90% of the nominal output voltage. All specifications valid at nominal input voltage, full load and +25°C after warm-up time unless otherwise stated. http://www.tracopower.com Page 6 of 8 Battery Controller Module TSP-BCMU360 Series 360 Watt Connector Position Top View Bottom View AC OK Bat. OK DC OK Remote On/Off Temp. Sensor (TS) Remote On/Off Side View Recommended switch specifications for operation with a switch: Front View A: Battery test period 10 min (not fitted, default); 15 sec (fitted) 5V / 5mA B: Output voltage settings 48 V (not fitted); 24 V (fitted, default) C: Not in use (spare jumper fitted) For direct pulldown operation, the voltage level has to be <1.0V Outline Dimensions 6.4 19.3 Detail A  DC-IN Bat OK DC OK Batter y Temp. Remote Weight: 1.102lb OK Sensor ON/OFF 3.8 Gewicht: 0.500kg Signal Connector 13.5 * Measurment from front panel to DIN Rail 113 ± 1* 54 ± 1 110 ± 1 10.2 11.6 M4 Combi Head (QTY: 8) -- 10.7 DC-IN-OK IN-1 IN-2 IN-1 IN-2 DIN-Rail 24 V/15 A DC-IN-OK BATT-OK 48 V/7,5 A Hook DC-OUT-OK BATT-OK DC-OUT-OK BATTERY VOLTAGE Battery Voltage Adjust ADJUST 10.9 8.1 F40A FUSE Battery Controller MODEL TSP-BCMU360 24 V/15 A 13,8V/30A 48 V/7,5 A BATT-IN OUTPUT -- 11.7 Jumper: 10.2 Battery Test Period/ M2 Combi Head Output Voltage Select (QTY: 10) 19 Weight: 730 g http://www.tracopower.com Page 7 of 8 3 10 110 ± 1 11.9 11.7 3.6 81.1 75.5 69.9 61.8 36.4 8.5 8.5 Battery Controller Module TSP-BCMU360 Series 360 Watt TSP–WMK Wall Mounting Bracket Ordercode of Kit For Models Content of Kit TSP-BCMU360 1 bracket TSP-WMK03 TSP-WMK03 85.0 (3.35) 42.5 (1.67) 34.5 (1.36) 34.5 (1.36) ø 4.25 (0.17) ø 4.25 (0.17) ø 4.25 (0.17) R 2.12 (0.083) 4 x positioning holes 2.0 (0.08) 15.0 15.0 (0.59) (0.59) Material: 2 mm Mild Steel Tolerance: ±0.1mm (± 0.004) 46.0 (1.81) TSP 360 33.0 (1.30) 96.0 (3.78) 25 (0.98) ø 4.3 (0.17) 2x ø4.3 (0.17) TSP 600 4 x positioning holes 173.0 (6.81) 15.0 (0.59) Material: 2 mm Mild Steel Tolerance: ±0.1mm (± 0.004) Dimensions: [mm] ( ) = Inch Specifications can be changed without notice! Make sure you are using the latest documentation, downloadable at www.tracopower.com Rev. November 28. 2017 www.tracopower.com Page 8 of 8 30.0 (1.18) 2.0 (0.08) 2.0 (0.08) 7.0 (0.28) 7.0 (0.28) 50.0 (1.97) R 2.12 (0.083) R 2.12 (0.083) R 2.12 (0.083) 2.0 (0.08) 2.0 (0.08) 2.0 (0.08) 62.5 (2.46) 25.0 (0.98) 25.0 (0.98) 37.0 (1.45) 74.0 (2.91) 62.5 (2.46) 55.0 (2.16)