User Operating Manual

DAU Alarm Module

Document Number: D140044-E001

Dale Power Solutions Ltd

Salter Road, Eastfield Industrial Estate, Scarborough, North Yorkshire, YO11 3DU, UK
info@dalepowersolutions.com | www.dalepowersolutions.com | +44 (0) 1723 583511
Revision History

0 Reproduced from legacy document S5101GU01 SW NP TMJ 27/01/20

Revision History By Check Appr’d Date
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Table of Contents
Revision History................................................................................................................................... 1
1. Safety ........................................................................................................................................... 3
2. DAU Alarm Module ....................................................................................................................... 4
2.1 Operating Modes ................................................................................................................... 4
2.2 Functions and Features ......................................................................................................... 5
2.2.1 Instrumentation .................................................................................................................. 5
2.2.2 Local and Remote Alarms and Indications ......................................................................... 5
2.2.3 Front Panel Control and Dispaly ........................................................................................ 6
2.2.4 Information Pages .............................................................................................................. 7
2.2.5 DAU Set Up Pages ............................................................................................................ 8
2.3 Equalise Mode Operation ...................................................................................................... 9
2.3.1 Equalise Selection ........................................................................................................... 10
2.3.2 Float Selection ................................................................................................................. 10
2.4 Battery Test ......................................................................................................................... 11
2.4.1 Battery Discharge Test Parameters ................................................................................. 12
2.5 Battery High Impedance Alarm ............................................................................................ 12
2.5.1 Setting up the High Impedance Alarm .............................................................................. 12
2.6 Set Up Page Selection......................................................................................................... 13
2.7 Alarm Set Up ....................................................................................................................... 15
2.8 Interface Module .................................................................................................................. 18
2.9 8 Relay Expansion Module .................................................................................................. 19
2.10 Remote Communications Module ........................................................................................ 19

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1. Safety

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Please read this manual prior to use to become familiar with the product’s numerous features and
operating procedures. To obtain a maximum degree of safety, follow the sequences as outlined.
To clarify certain points within this manual to ensure proper and safe operation of the equipment, the
following emphasis is used.

Highlights an essential element of a procedure to ensure correctness.

NOTE:-

Highlights an essential element of a procedure for installation or

NOTE:- maintenance to ensure correctness.

Indicates a procedure or practice which, if not strictly observed, could

CAUTION:- result in damage or destruction of equipment.

Indicates a procedure or practice which could result in injury to

WARNING:- personnel or loss of life if not followed correctly.

Before using the product, read all instructions and cautionary markings on the product and any equipment
connected to the product.

Do not expose the product to rain or snow; install only in a clean, dry environment.

CAUTION!:- Unless otherwise noted, use of an attachment not recommended or sold by the product
manufacturer may result in a risk of fire, electric shock, or injury to persons.

CAUTION!:- Do not operate the product if it has received a sharp blow, it has been dropped, or otherwise
damaged in any way – return it to a qualified service centre for repair.

CAUTION!:- Do not disassemble the product – call our qualified service centres for servicing. Incorrect
reassembling may result in a risk of electrical shock or fire.

WARNING!:- The output voltages of the product are hazardous. Extreme caution should be maintained
when servicing or touching conductive components connected to the product’s output.

Dale Power Solutions own the copyright to this manual, which may not be copied, reproduced
or disclosed to a third party without prior written permission.

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2. DAU Alarm module

This module provides system instrumentation, control and alarm functionality for single or three phase
thyristor charger systems. The device consists of a display/user interface module which is normally
front panel mounted, and a system interface module located within the panel.

2.1 Operating modes

The DAU user interface has four modes (levels) of operation: User Mode, User Set-Up Mode,
Engineer Mode and Service Mode.

USER MODE: this is the normal mode of operation. The user has access to all the screens contained
in the user level. These provide system measurements, charger mode & system alarm status
information and allow selective control of the system.

USER SET-UP MODE: provides access to all the user settable parameters screens. Entry into this
mode is optionally protected by a user-changeable 4 digit password, which is default set as blank.

NOTE: PLEASE KEEP A RECORD OF YOUR PASSWORD if you change it, as once you exit this
mode you will be denied access in future without entry of the correct password.

ENGINEER MODE: provides access to all the engineer settable parameters screens. These allow the
various alarm settings and control features, to be configured or adjusted during factory testing of the
system. These functions are password protected and are not accessible to the user.

SERVICE MODE: the unit functions as in engineer mode but also unlocks restricted access features
such as analogue input calibration and control output testing.

These functions are password protected and are not accessible to the user.

The Navigation around these screens, and adjustment of the various parameters is achieved by using
the push buttons, which are present on the front panel user interface module the function of which is
described below.

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2.2 Functions and features

2.2.1 Instrumentation

The module provides an LCD display for the indication of the charger output voltage and current.
Indications have an accuracy of ±1.5% or better. The display also serves for programming the
system control and alarm functions. In the instrumentation mode, the display indicates both voltage
and current.

2.2.2 Local and remote alarms and indications

Facilities are provided for alarm reset, and LED test. All local LED indications are configurable
individually to be reset manually or automatically. All alarm settings have an adjustable time delay of
up to at least 30 seconds. In addition to the front panel time delayed LED for each alarm function, an
internally located red LED illuminates as soon as the alarm condition is initiated i.e. before the
adjustable time delay. All alarm and control functions are individually configurable from the front panel
display module.

Alarm / LED Colour Function

Function
Supply on Green The charger is on and receiving an AC supply.
Note: AC Supply On does not indicate if the AC supply is present at the cubicle input
terminals if the charger has been switched off via its input circuit breaker. Isolate elsewhere.
Supply fail Yellow Indicates that the normal supply is not present, i.e. Charger is off
and does not have an AC supply (see note above).
Equalise Yellow Selection of a higher charger output voltage.
When enabled can be selected for Manual or Automatic Equalise
following an AC supply failure.
This feature is normally disabled on systems supplying VRLA
batteries.
DC low volts Yellow Indicates that the DC voltage is below the pre-set level.
DC high volts Yellow Indicates that DC voltage is above a pre-set level. The alarm
setting threshold is raised as required when the system is
selected for the equalise charge mode to prevent nuisance
tripping.
Earth fault Yellow Operates when the insulation resistance of either the positive or
(only when negative poles to earth falls below a pre-set level and the other
enabled) pole stays above 2M. A remote Earth Fault signal can also be
mapped to this LED.
Charger fail Red Both the voltage and current from the charger are below the pre-
set levels.
High volts trip Red As well as the high DC volts alarm it is also possible to set the
DAU to trip the charger input circuit breaker if the DC voltage rises
above the set point.
High battery Red This indicates when the internal resistance of the battery rises to a
impedance (only when level that would prevent it from operating satisfactorily on load. A
enabled) remote High Impedance signal can also be mapped to this LED.

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 DC Low Volts Red Fault LED This feature, when enabled, is provided to operate a contactor to
Disconnect (on display disconnect the battery from the load when the DC voltage falls
when enabled) below a pre-set level. Automatically resets on resumption of
battery charging.
Remote Red Fault LED Inputs are provided to monitor up to five digital inputs. When
Inputs (on display active the input’s label will be shown on the display and
when enabled) incorporated into the group alarms
Remote The DAU is equipped as standard with two output changeover
Outputs relays to which the above alarms can be mapped.
Remote The DAU can be connected to an optional separate eight relay
expansion module for additional remote alarm indication or system functions.
relays

2.2.3 Front panel control and display

The unit incorporates a screen for the display of system parameters and operator interaction during
system set-up or interrogation and set-up routines.

The system has display pages giving the system parameters. The left arrow and right arrow push
button will allow an operator to cycle through and select the required page.

The control push buttons are detailed below. On each page of the DAU display, the ‘active’ keys
(those which may be selected), are shown on the bottom line of the display.

Push Button Functions

During set-up mode this pushbutton will increment a parameter. From the Metering page
this shows the earth fault levels and battery impedance setting.
During set-up mode this pushbutton will decrement a parameter.

This button moves the displayed page to the next one on the left allowing the operator to
cycle through the display pages. During set-up mode this pushbutton will allow navigation
to the required set up page. Also used to move between the digits of the password and
other numeric parameters in set up.
This button moves the displayed page to the next one on the right allowing the operator to
cycle through the display pages in a reverse order to that of the left arrow pushbutton.
During set-up mode this functions as per the left arrow.
In normal mode this push button will cause the display to go to the home page which
displays the system voltage. While in set-up mode this button will cause the unit to exit
from the currently displayed page to the home page in the current level of the set-up mode
page structure. Referred to as Home in the setting up instructions.
In normal mode, this pushbutton will allow the operator to enter a password code to gain
access into set-up mode. Entry to set-up mode is protected by a 4-digit number (see
System Settings for details), which the operator must set with the arrow keys. During set-
up mode this pushbutton will accept the displayed settings of the parameter or value.
Referred to as Return in the setting up instructions.
During normal mode this pushbutton will cause all, except the AC Supply On, front panel
LED alarm indicators of the unit to illuminate.
During normal operation, this pushbutton will clear any latched alarms.

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2.2.4 Information pages

The pages are displayed during normal operation and give an overview of the system voltage and
current, status, and any alarms.

No changes can be made to the system from these pages.

Page Display
Metering • DC Voltage(s) • Battery impedance
• Current drawn by the load • Earth fault Vpos
from the system • Earth fault Vneg
(Use Up arrow to access)
Active Alarms • Any individual active and latched alarms and their groups

Charger Mode The current state of the system e.g.

• Float charging
• Equalise charging and timer period
• Charge fail
Battery Test • For selection fo the battery test mode when enabled

Earth Fault Test Available for positive and negative if the test circuit is included in
the system design
Battery High Impedance Test Available if the test circuit is included in the system design

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2.2.5 DAU Set up pages

The chart below shows the pages in order. From any of these pages the use of the Home button returns you to the System overview page. From this
page Home displays the software version information.

When the DAU is first powered up, it will flash up information about the unit for several seconds, before displaying the System Voltage and Current.

The display pages can be scrolled through, by using the left and right arrow keys. Pressing the RETURN key at any of these pages, allows the user to
enter the selected password, gaining access to the Set Up pages as shown below.

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2.3 Equalise mode operation

The unit allows five different options for the mode of operation for the Equalise function.

In the first mode, the equalise function is disabled.

In the second mode, manual selection only is possible. A timed equalise charge is provided, which
may be manually terminated at any point, see below.

The third mode, enables automatic and manual initiation of the function. In this mode the equalise
function can be manually selected at any time, unless there is a charge fail alarm present.

When equalise is selected the output of the charger will start to rise, at a rate depending on the
capacity and state of charge of the batteries, until the Knee Point is reached. This is the point at
which the charging mode changes from constant current to constant voltage. The pre set equalise
timer period is now started and the charger will return to float when this is timed out (or a charge
failure occurs).

In this mode, a charge fail will automatically start an equalisation cycle, which can be terminated
manually at any time as shown below.

The fourth mode allows manual equalise with a remote enable.

This modes allows the manual selection of equalise as above provided that the Remote Mode Control
(RMC) input is active. If not present this will inhibit the selection of equalise, e.g. equalise charging of
the battery can be inhibited if a signal for ventilation fan failure is present.

In the fifth mode, the unit functions as a slave unit which is remotely controlled from a master device
using the RMC input; e.g. a system level Charge Fail Auto Equalise (CFAE) module. In this mode the
state of the RMC input determines the chargers equalisation mode. It will indicate the present mode of
operation but all manual control is disabled.

Set up page Function Setting range

Equalise • DISABLE: Float only, normally selected for VRLA batteries
Mode • MANUAL ONLY: Manual timed selection from the DAU fascia
• MANUAL / AUTO: DAU controls the equalise function
• REMOTE ENABLE: Manual selection of equalise from DAU
fascia but is enable or disabled remotely
• REMOTE CONTROLLED: DAU acts as a slave and equalise
is initiated from only a remote contact
Charge Fail The voltage at which the auto equalise cycle is enabled. 75 – 100% of
Trip nominal

Charge Fail The voltage at which the charge is switched into equalise. 100 – 140% of
Reset nominal
Charge Fail Time between the charge fail set point being reached and its 0 – 120s
Delay activation.
Knee Volts The point at which the battery goes from constant current to 100 – 125% of
constant voltage charging and the equalise timer is started. nominal
Equalise The time which the charge is in equalise mode after the knee volts 0.5 – 48h
Timer point has been reached. Charge returns to float mode.

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2.3.1 Equalise selection

When the Manual only or Manual/Auto mode is enabled Equalise is selected by pressing the UP key
as shown below.

Charger Mode Note: Equalise selection is inhibited when the Charge

Mode = FLOAT Fail alarm is active.
Press [UP] to start
Equalise

Charger Mode The charger is now in the *Note that the time is
Mode = EQUALISE equalise mode. To return to only shown once the
Time left = 12hours* float press knee point is reached
Press [DOWN] to stop

2.3.2 Float selection

At any point during the equalise period the charger can be returned to the float mode as shown
above.

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2.4 Battery test

A feature of the DAU allowing the battery to be discharged into the site loads, this cannot be enabled
in the field as extra interconnection and set up is required at the manufacturing stage. This option
gives confidence in the battery to support the load in the event of a mains failure. To do this the
charger is shut back to a lower voltage (pre set) to allow the battery to discharge into the load and to
be on standby in case of a battery failure. A failure of the test will cause an alarm.

This feature checks the suitability of the battery to support the site load for a given time or for a pre-
set capacity but does not check the full battery capacity.

A test is terminated by voltage or time. If the battery voltage drops below the set level before the
timer period has elapsed then the test is failed. If the time is reached before the voltage drops to the
set level then the battery has passed. See system specification for settings and details below on
setting up and adjustments.

Battery Test Note: Battery test is inhibited when the Charge Fail
alarm is active.
Press [UP] to start
Battery Test

Battery Test The charger is now in the

Mode = Battery Test shut back mode. To return to
float press
Press [DOWN] to stop

Note: Battery Test is inhibited if the AC Supply Fail, Charge Fail, or a

previous Battery Test Failed alarm is present or the charger is in equalise
mode. This will appear on the display.

If the battery fails the discharge test then a latched alarm is generated. This will inhibit any further
battery discharge until reset with the push button.

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2.4.1 Battery discharge test parameters

These are accessed as described below.

Set up page Function Setting range

Manual Enable or Disable the function
Battery Test
Battery Test • Battery test minimum volts. 75 – 125%
Fail Voltage The voltage at which the battery is deemed to have failed the
test if this point is reached before the time/capacity has been
exceeded
Battery Test • Maximum time: 1 – 60m
Time The test is terminated after a set time has elapsed provided
that the voltage stays above the set level

2.5 Battery High Impedance alarm

This alarm continuously monitors the battery and its connections for any increase in their impedance
which may affect the ability to support the load in the event of a mains failure. This option cannot be
enabled in the field as extra hardware and set up is required at the manufacturing stage.

2.5.1 Setting up the High Impedance alarm

First the system and its batteries should be connected and fully installed.

Enter the set up pages from the Metering information page using the user password, as described
below and you will be in the High Impedance Alarm set up page.

Press RETURN twice to reach High Impedance Trip = xx Ohms. This shows the current setting.
Reduce the setting, using the DOWN arrow until the alarm is tripped; this is done by checking the
LED on the system interface board as this does not have a time delay. Now increase the setting until
the alarm is cleared. If any nuisance alarms occur the setting can be increased accordingly. Press
RETURN to move to the High Impedance Delay page. This is set to 30 seconds as default and can
be adjusted if required although reducing it may cause nuisance alarms. To save the changes press
the HOME button twice to return to the information pages.

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2.6 Set up page selection

By use of a password (the default is blank) the set up pages of the DAU can be accessed.

Pressing the RETURN key on all information pages will take you to the password screen as shown
below. After entering the password, press the return button and after a short delay to display the
‘Entering Set Up Mode’ Message you are in the set up pages.

The first page displayed depends on the screen from which Set Up is selected:

Information page User set up mode page

Metering High Impedance Alarm Set Up Pages
Active alarms High Impedance Alarm Set Up Pages
Charger Mode Equalise Set Up Pages
Battery Test Battery Test Set Up Pages
Positive or Negative Earth Fault Test Earth Fault Set Up Pages
Battery High Impedance Test High Impedance Alarm Set Up Pages

Navigation to the other pages is via the  and buttons. RETURN takes you into the relevant pages
and Home will take you back to the Information Pages.

Note; ‘Saving Settings to Non Volatile Memory’ will always be displayed briefly when coming out of
the set-up menus, even if changes have not been made.

If, when you access a set of pages, it is decided that another page of screens is required the Home
button will take you back to the selection level.

NOTE: In Dale Power Solutions supplied systems, the DAU has been factory set in
accordance with your specification, and for the correct operation of the system. Before making
any changes to its settings first check that they do not affect the operation or safety of the
system. Any changes should be limited to alarm and battery test settings only. Other alarm
functions are available within the DAU but are protected by a further password which is
available on request. If in doubt, please contact Dale Power Solutions UPS Service
Department.

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Access to some User Set Up pages is restricted by the Engineering Mode password.

Changes can be made to High Volts Shutdown, Low Volts Disconnect and other system function parameters, however, due to the fact that these
affect system safety and operation they are protected by an Engineering Mode password available from Dale Power Solutions on request.

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2.7 Alarm set up

All of the alarm pages have the following parameters:

Trip: The point at which the alarm is activated (on a
falling voltage for low volt alarms or a rising voltage
for high volt alarms)
Reset: the point at which the alarm is cleared (on a
rising voltage for low volt alarms or a falling voltage
for high volt alarms).
Delay: the period between the alarm being activated
and it being displayed on the front panel and
activation of the remote relay. Note that the LEDs on
the interface module (see below) are activated
instantaneously.
Latch: when enabled the alarm will latch on the
display and remote relay once the time period has
elapsed. To clear the alarm the level must first be
past the reset level and the Alarm Reset button is
pressed. Note that the LEDs on the interface board
are non latching.
Common Alarm Mapping: selects the remote relay
activated by the alarm.
Expansion Relay Mapping: selects the relay on the
expansion module (if fitted) activated by the alarm.

To enter any of the alarm set up pages press

RETURN at the desired page. The values are
altered with the UP and DOWN buttons. Press
RETURN to carry on to the next page or HOME to
return to the selection page.

Any changes made are automatically saved when the

RETURN or HOME buttons are pressed and you
return to the information pages. There is no option
to cancel the changes.

The diagram to the right shows an example page. All

others are of a similar format.

The table below shows all alarms, the pages in the

order they appear as RETURN is pressed.
A brief explanation of the alarm is given and the limits
of the settings. Voltage alarms are shown as a
percentage of the nominal system volts, 24V, 50V,
110V etc.

*Note :- the +Vs & +Vp terminals allow the voltage to

be sensed at either side of a charger output blocking
diode for systems built with this feature. Vs is
connected to the charger side of this diode and Vp is
connected at the system side. This function can be
configured to use the +Vp input only for systems
without a blocking diode.

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Battery High Impedance Resistance of battery circuit at +Ps terminal. Alarms if the
impedance rises above the set point. Resets on low
impedance.
Enable/Disable
Trip Ohms 0.2 – 5.0 Ohm Reset set point less 0.2 Ohm
Delay 0 – 120s
Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

Earth Fault Fault Current +Vp terminal. Alarms when the resistance to
earth either the positive OR negative pole of the DC is low
enough to cause a current, above the set point to flow, in
the earth if a low impedance return path were present.
The other pole must be above 2M.
Trip mA 1,2,4,10mA
Delay 0 – 120s
Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

Low Volts Alarm Voltage sensed at +Vp terminal. Alarms on a falling

voltage, resets on rising voltage.
Trip V 75 – 125%
Reset V 100 – 140%
Delay 0 – 120s
Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

Charger Fail Alarm Voltage sensed at +Vs terminal and current sensed at
charger output shunt. Alarms on a falling voltage AND
falling current , resets on rising voltage OR current.
When AC Fail Active • Enable – CF will alarm when AC failed.
• Disable – CF will not alarm when AC failed.
Trip V 75 – 125%
Reset V 100 – 140%
No Access to these Trip A Fixed at <10% of shunt rating Non adjustable
settings Reset A Fixed at >20% of shunt rating Non adjustable
Delay 0 – 120s
Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

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 High Volts Alarm Voltage sensed at +Vp terminal. Alarms on a rising
voltage, resets on falling voltage.
Trip (float) V 100 – 140%
Reset (float) V 75 – 100%
Trip (Equalise) V 100 – 140%
Reset (Equalise) V 75 – 100%
Delay 0 – 120s
Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

AC Fail AC derived voltage received from charger controller.

Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

The following alarms are accessed only through the Engineering Mode password.

High Volts Shutdown Voltage sensed at +Vs terminal. Alarms on a rising

voltage, resets on falling voltage.
Mode • Internal – DAU controls shutdown
• External – Charger controls shutdown, DAU marshals
alarm only.
Trip (float) V 100 – 140%
Reset (float) V 75 – 100%
Trip (Equalise) V 100 – 140%
Reset (Equalise) V 75 – 100%
Delay 0 – 120 secs
Latch Enable/Disable
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

Low Volts Disconnect Voltage sensed at +Vp terminal. Alarms on a falling

voltage, resets on rising voltage. Used to drive a battery
or load contactor to disconnect and protect a VRLA
battery or for load shedding.
Trip V 75 – 125%
Reset V 100 – 140%
Delay 0 – 120s
Common alarm relay mapping 1 or 2
Expansion relay mapping 1 to 8

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2.8 Interface module

The eight LEDs in the bottom left hand corner, work independently of the LEDs on the Display
Module. They immediately indicate that the respective alarm is active. The front display LEDs do not
light until after the time delay has elapsed. This is used for testing and commissioning the alarm
functions.

The Interface is connected to the Display via a null

modem 9 way D Type connector on CON5, and (if
relevant) to the DCV charger controller by a 20 way
ribbon cable on X16. All other connections are via the
two part connectors listed below.

Function RC
1.1 Group 1 volt free alarm (NO)
1.2 Group 1 volt free alarm (COM)
1.3 Group 1 volt free alarm (NC)
2.1 Group 2 volt free alarm (NO)
2.2 Group 2 volt free alarm (COM)
2.3 Group 2 volt free alarm (NC)
E Earth fault alarm ground connection
+12 High Volts Shut Down
HVSD High Volts Shut Down
-PS Power supply –Ve
+VS System voltage sense +Ve
-COM Voltage sense common –Ve
+VP Charger voltage sense +Ve
+PS Power supply +Ve
-A Current sense 75mV –Ve ✓
+A Current sense 75mV +Ve ✓
COM Charger common ✓
P AC Supply On from charger ✓
FC Remote fault input common
FC Remote fault input common
RMC Remote control mode input
F1 Remote fault input 1
F2 Remote fault input 2
F3 Remote fault input 3
F4 Remote fault input 4
F5 Remote fault input 5

All connection marked ✓ in the RC column are connected to the DCV controller via the 20 way ribbon
cable on X16.

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2.9 8 Relay expansion module

When incorporated into a system this is connected to the DAU via a 10 way ribbon cable. One or
more alarms can be mapped to one or more relays using the ‘Expansion Relay Mapping’ page and
changing the position to [X]. The LED indicates when the relay is energised. Each relay (K) provides
a set of volt free change over contacts via the corresponding terminal block (X). The relay can be
configured, within the DAU Engineering mode, to energise or de-energise on alarm.

2.10 Remote communications module

A communications adaptor is available to provide remote monitoring of the system via a Modbus
Communications Module. Additional documentation will be provided when this feature is included in a
system design.

Document ends.

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