Open frame UPS for industrial designs

September 02, 2021 // By Nick Flaherty
Open frame UPS for industrial designs
The UPSI-2412 from Bicker Elektronik is an intelligent 24V DC emergency power supply for integration into industrial systems with extensive configuration options

Bicker Elektronik in Germany has developed an intelligent 24V DC emergency power supply for integration into industrial systems.

The UPSI-2412 is a combination of LiFePO4 or Supercap energy storage devices to bridge power failures and brownouts and ensure an uninterruptible 24 VDC supply.

The DC UPS board UPSI-2412 is designed for flexible open-frame system integration in customer-specific applications and enables individual emergency power supply solutions for long-term use in the fields of Industry 4.0, medical and laboratory technology, renewable energy, control and regulation technology, safety, vision and inspection systems.

In normal operation, the UPSI-2412 forwards the DC input voltage directly to the output, charges the connected energy storage device in parallel and monitors all relevant parameters, currents and voltages. In the event of a voltage drop or power failure, a MOSFET disconnects the input within a few microseconds and the connected load is supplied without interruption from the energy storage device and the UPSI-2412 provides a constantly regulated DC output voltage.

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The intelligent power sharing function is implemented at the DC input to avoid the upstream AC-DC power supply being over-dimensioned, but still ensuring the input power is kept constant and distributed accordingly to the load and the charger. This means that when there is a low load at the output, more energy flows into the charger and vice versa.

To ensure that the UPSI-2412 can be used flexibly with different storage technologies, three charging processes with individual adjustment of the end-of-charge voltage and a charging current of up to 4.5A are implemented: Constant Current, Constant Voltage and Constant Power. The integrated microcontroller (µC) recognizes the type and data of the Bicker energy pack, so that the charging and discharging parameters can be individually adjusted.

Bicker offers maintenance-free supercaps as highly efficient and particularly long-lasting energy storage devices with more than 500,000 charge and discharge cycles. The EDLC supercaps based on electrophysical principles and are charged and ready for use within a very short time. Under comparable operating conditions, Supercap energy storage devices have a service life that is up to ten times longer than classic lead-acid batteries. Energy packs with Supercapacitors also impress with their high current carrying capacity, power density and reliability.

Lithium iron phosphate technology with a high energy density is ideal for longer backup times. The high-performance battery packs of the BP-LFP series are a particularly stable battery chemistry, high cycle stability and a long service life of at least 10 years for safety applications. The integrated battery management system (BMS) with cell balancing ensures that all cells are charged evenly so that the full capacity of the battery pack can be used over the long term. In contrast to lead-acid batteries, high-quality lithium iron phosphate cells have an approx. 15-20x longer service life and cycle stability. In addition, 100% of the full nominal capacity of the LiFePO4 battery pack can be drawn continuously. Conventional lead-acid batteries have significant limitations in terms of DoD (Depth of Discharge) and number of cycles. When calculating the TCO (Total Cost of Ownership) over the entire period of use of at least 10 years, there is a clear cost advantage compared to lead-acid batteries, especially since the effort for maintenance and battery replacement for LiFePO4 is eliminated during this period.

For mobile applications, the UPSI-2412 has the option of starting the supplied application from the battery with a maximum load current of 7A without a mains-side power supply being available or connected. Bicker recommends the LiFePO4 high-performance battery pack BP-LFP-2725 is used for this. 
The UPSI-2412 also has an integrated USB interface for connection to an IPC system and is recognized directly by the operating system as a UPS without additional drivers or software installation.

Next: UPS configuration tool

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