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FULL REDUNDANCY DC POWER SYSTEM

MODEL PS1UDC+

USER GUIDE

Release 2.0, March 2012

Har Hotzvim Industrial Park,


14 Hartom St., P.O.B. 45029, Jerusalem 91450, Israel
Tel: 972-2-588-8222 Fax: 972-2-582-8875
Email: info@gamatronic.co.il Website: www.gamatronic.com
Gamatronic Electronic Industries Ltd.
Har Hotzvim Industrial Park
14 Hartom St., PO Box 45029, Jerusalem 91450 Israel
Tel: +972-2-588-8222 Fax: +972-2-582-8875
Email: info@gamatronic.co.il Website: www.gamatronic.com

The equipment described in this document is not intended to be used in connection with any
application requiring fail-safe performance, unless the application design includes appropriate
redundancy. This exclusion includes, but is not limited to, the direct operation of any life support
system or any other system whose failure could lead to serious injury, death, environmental damage or
mass destruction.

 Copyright 2012 by Gamatronic Electronic Industries Ltd. All rights reserved worldwide.
Gamatronic Electronic Industries Ltd. ("Gamatronic") warrants the products it manufactures to be free from defect for a period of one
calendar year from the date of purchase by the end user, including the date of purchase. Gamatronic's liability is limited to repairing or
replacing any defective parts in the equipment under warranty. Gamatronic reserves the right to determine whether the repair work
shall be performed at Gamatronic's factory, at the customer's premises, or at an alternate site. The customer must obtain authorization
from Gamatronic before returning any parts or equipment to Gamatronic for repair or replacement. Any items returned to Gamatronic
must be sent freight prepaid.
Gamatronic is not responsible for any damage to the product due to unauthorized repair work, misuse or abuse of the product, or force
majeure.
Gamatronic is not liable for and the Purchaser waives any right of action it has or may have against Gamatronic for any consequential
or special damages arising out of any breach of warranty, and for any damages that the Purchaser may claim for damage to any
property or injury or death to any person arising out of its purchase or the use, operation or maintenance of the subject product.
This warranty includes parts and labor; however, Gamatronic shall not be responsible for any labor subcontracted or performed by the
Purchaser to prepare the warranted item for return to Gamatronic or Gamatronic's agent.
Any representations in this document concerning the performance of Gamatronic's product(s) are for informational purposes only and
are not warranties of future performance, either express or implied. Gamatronic's standard limited warranty, stated in its sales contract
or order confirmation form, is the only warranty offered by Gamatronic Electronic Industries Ltd. in relation thereto.
The information contained in this document is proprietary and is subject to all relevant copyright, patent and other laws protecting
intellectual property, as well as any specific agreement protecting Gamatronic's rights in the aforesaid information. Neither this
document nor the information contained herein may be published, reproduced or disclosed to third parties, in whole or in part, without
the express, prior, written permission of Gamatronic. In addition, any use of this document or the information contained herein for any
purposes other than those for which it was disclosed is strictly forbidden.
Gamatronic reserves the right, without prior notice or liability, to make changes in equipment design or specifications.
Information supplied by Gamatronic is believed to be accurate and reliable. However, no responsibility is assumed by Gamatronic for
the use thereof nor for the rights of third parties which may be affected in any way by the use thereof.
This document may contain flaws, omissions or typesetting errors; no warranty is granted nor liability assumed in relation thereto
unless specifically undertaken in Gamatronic Electronic Industries Ltd. sales contract or order confirmation. Information contained
herein is periodically updated and changes will be incorporated into subsequent editions. If you have encountered an error, please
notify Gamatronic Electronic Industries Ltd. All specifications are subject to change without prior notice.

This book describes the following products:


PRODUCT DESCRIPTION CATALOG NUMBER
PS1UDC+ power supply 48 V / 33 A 1020480033\1PTK
PS1UDC+ power supply 48 V / 33 A LLC 1020480033-LLC
PS1UDC+ power supply 24 V / 40 A LLC 1020240040-LLC

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TABLE OF CONTENTS
1. INTRODUCTION ....................................................................................................1
1.1 Model types ...............................................................................................1
1.2 Line input ...................................................................................................1
2. SYSTEM DESCRIPTION .......................................................................................2
2.1 Overview ....................................................................................................2
2.2 Main features .............................................................................................3
2.3 Front panel view .......................................................................................4
2.4 Rear panel view .........................................................................................4
2.5 Shelf connections and jumpers ...............................................................5
3. THE RECTIFIER MODULE ....................................................................................7
3.1 Simplified block diagram of a rectifier module ......................................7
3.2 Views of a rectifier module ......................................................................8
3.3 Rear panel of a rectifier ............................................................................9
3.4 Rectifier calibration ................................................................................10
4. TECHNICAL SPECIFICATIONS ..........................................................................11
4.1 Technical specifications for the standard PS1UDC+ system .............12
4.2 Specifications for the standard PS1UDC+ rectifier module ................13
4.3 Technical specifications for the PS1UDC+ LLC system .....................14
4.4 Specifications for the PS1UDC+ LLC rectifier module ........................15
5. SYSTEM CONTROLLER SC1UDC+ ...................................................................16
5.1 Controller front panel .............................................................................17
5.2 Battery test ..............................................................................................20
5.3 Rectifier addresses .................................................................................21
6. ELVD (ELECTRONIC LOW-VOLTAGE DISCONNECT DEVICE) ......................22
7. INSTALLATION PROCEDURES .........................................................................23
7.1 Safety instructions ..................................................................................23
7.2 General ....................................................................................................23
7.3 Fuses .......................................................................................................24
7.4 Installing the system ..............................................................................24
7.5 Output dry contacts ................................................................................24
7.6 Input dry contacts ...................................................................................27
7.7 Battery temperature compensation ......................................................28
8. COMPUTATIONS .................................................................................................29
9. TROUBLESHOOTING .........................................................................................31

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LIST OF FIGURES

Figure 1: Example of PS1UDC+ system with controller and 11 rectifiers ......................... vi


U U

Figure 2: Block diagram of the PS1UDC+ power system..................................................... 2


U U

Figure 3: Front panel of the PS1UDC+(Shelf types 1 and 2) ................................................ 4


U U

Figure 4: Rear view of the PS1UDC+ ..................................................................................... 4


U U

Figure 5: Shelf connections and jumpers on system rear side ........................................... 5


U U

Figure 6: Rectifier LED bar-graph of load ............................................................................... 7


U U

Figure 7: Block diagram of a rectifier module....................................................................... 7


U U

Figure 8: Views of a rectifier module ..................................................................................... 8


U U

Figure 9: Rear panel of a rectifier module ............................................................................. 9


U U

Figure 10: Rectifier calibration point ................................................................................... 10


U U

Figure 11: System controller SC1UDC+............................................................................... 16


U U

Figure 12: Front panel of system controller SC1UDC+ ...................................................... 17


U U

Figure 13: Address assignments for 38 rectifiers with controller ..................................... 21


U U

Figure 14: Relative dc voltage levels ................................................................................... 26


U U

Figure 15: Connections for battery temperature sensors .................................................. 28


U U

LIST OF TABLES

Table 1: Key to Figure 4 .......................................................................................................... 4


U U

Table 2: Jumper settings for system shelves ........................................................................ 6


U U

Table 3: Pin assignments on rectifier module rear panel ..................................................... 9


U U

Table 4: LED indicator lights ................................................................................................ 18


U U

Table 5: Function buttons on the front panel ...................................................................... 19


U U

Table 6: Factory std. assgnmnt of syst. alarms to output dry contacts ........................... 26
U U

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Figure 1: Example of PS1UDC+ system with controller and 11 rectifiers

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1. INTRODUCTION
The Gamatronic "PS1UDC+" power system:

• Provides clean dc power to sensitive equipment such as telecom exchanges and


transmission systems, other switching systems, industrial systems for automatic control and
process supervision.
• Charges the battery bank that provides backup power during a mains failure.

The PS1UDC+ is essentially a dc-UPS with a battery connected to it. The size of the battery
determines the duration of the backup provided and the current needed to recharge the battery
when they have become discharged following a lengthy power failure. (See Computations, page
29 for how to determine appropriate battery size.)

The PS1UDC+ system makes use of two techniques to achieve continuity of power supply to the
load:

• Redundancy of rectifiers. The system is provided with one or more rectifiers above and
beyond the number needed to power the maximum load and keep the battery charged. This
ensures that if one or more of the rectifiers were to fail, the system would remain capable of
supplying the maximum required power.
• Battery backup. In the event of a failure of the input ac power source, the batteries enable the
system to continue to power the load for a limited period of time.

1.1 Model types


There are two models of the PS1UDC+ power system:

• One model has a nominal output of 48 Vdc.


• The other model has a nominal output of 24 Vdc.

The 48 Vdc power system can use one of two types of rectifier modules:

• The standard module, with efficiency of up to 92 % for Vin=230 Vac.


• The LLC module, with improved efficiency of up to 96 % for Vin=230 Vac.

The 24 Vdc power system accepts only the LLC type of rectifier module,
with efficiency of up to 94 % for Vin=230 Vac.

1.2 Line input


The PS1UDC+ power system accepts line input of:

• one phase (three wires: Phase, Neutral, Ground),


OR
• three phases (5 wires: L1, L2, L3, Neutral, Ground).

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2. SYSTEM DESCRIPTION
2.1 Overview
The PS1UDC+ power system is comprised of four main subsystems:

• Rectifier module(s): Convert(s) ac input to dc output.


• Electronic Low Voltage Disconnect (ELVD) device: Disconnects the battery from the load,
preventing the damage to the battery that results from over-discharging. The PS1UDC+ has a
true semiconductor-based LVD with no moving parts (such as relays or contactors). This
ensures reliable operation and a long MTBF. The ELVD of the PS1UDC+ uses power
MOSFETs to perform the switching. The ELVD has two branches that can handle two
independent battery sets. (For loads higher than 120 A, battery disconnection is performed
by a dc contactor (LVD).)
• System controller: Monitors and controls the system and also communicates with an
external PC or network. This is done by an RS232 serial port (standard) or via
PPP/SNMP/TCP-IP protocol (optional).
• Motherboard

The rectifiers are “hot pluggable” and operate in parallel. This means the rectifiers can be added
or replaced with no impact on the power supply to the load devices and with no impact on the
battery charging current. The parallel configuration of the rectifiers also enables the user to define
an “N+1” or “N+2” redundant system.

Each rectifier has its own current sharing system, and provides complete, precise current sharing
among rectifiers.

Output terminals for connecting the load and battery sets are mounted on the connecting busbars
of the motherboard, located behind the removable metal rear panel.

OPTION: On customer request, the PS1UDC+ power system can include a special additional
rack containing dc–dc converters.

Figure 2: Block diagram of the PS1UDC+ power system

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2.2 Main features


• 1 to 38 parallel “hot-plugged” 1U rectifiers, each with a maximum output of
33 A / 48 Vdc or 40 A / 24 Vdc, for Vin=230 Vac.

• Maximum current rating of the power system is 1250 A. Actual rating depends on the number
of rectifier modules.

• System input voltage: single-phase or three-phase, as per customer request.

• Universal input voltage for the rectifiers: 100 to 240 Vac nominal continuous, no selectors or
switches.

• Smart rectifier modules with built-in microprocessor and high output power density.

• Input over-voltage protection: in the event that the input voltage to the LLC rectifier module
rises to ≥300 Vac, the rectifier module ceases operation. When the input voltage descends to
280 Vac, the rectifier module resumes normal operation.

• Power systems using LLC power modules are protected against mix-up of input phases,
neutral and ground wires, and against disconnection of neutral or phase wires

• A built-in dual ELVD for battery protection (2 x 70A | 1 x 120A). For higher current ratings a
special additional contactor (LVD) can be provided.

• A high performance, hot-pluggable 1U system controller measures, displays, and monitors


voltages, currents, temperature, battery parameters and other data. The system can be
operated with or without the controller.

• The controller has an LCD screen for the display of data and parameters.

• The system can be operated and monitored using a graphic software interface (Windows-
compatible) and a local or remote PC or laptop computer.

• Two battery sets provide redundancy.

• Automatic and programmed battery test.

• Two battery charge modes: float and equalize/boost.

• Temperature compensation varies the battery charging voltage in floating mode to enhance
battery life.

• Software updates can be applied to the PS1UDC+ remotely, with no physical intervention
required.

• Six programmable output dry-contact signals (N.O.) are available for transmittal of alarms or
signals.

• Eight input dry contacts are available to accept signals from external sources.

• Active current sharing between all the rectifiers for optimum performance.

• Controller and rectifier modules are hot-plugged, and can be replaced during system
operation with no interruption to the voltage supplied to the load or the batteries.

• Two types of shelves: for controller and two rectifiers (type 1), or for three rectifiers only
(type 2).

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2.3 Front panel view

Figure 3: Front panel of the PS1UDC+(Shelf types 1 and 2)

2.4 Rear panel view

Figure 4: Rear view of the PS1UDC+

Table 1: Key to Figure 4


ITEM DESCRIPTION
1 Connection for battery #1 (–) to ELVD, 70 A max. (See chapter 6 on page 22.)
2 Connection for battery #2 (–) to ELVD, 70 A max. (See chapter 6 on page 22.)
3 Load connection (–).
4 Load and batteries 1 and 2 connection (+).
5 Each rectifier has an ac input plug with three wires (Ground, Phase, Neutral).
6 Motherboard.

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2.5 Shelf connections and jumpers


The rear side of the PS1UDC+ system contains shelf connections and jumpers.

The connections and jumpers are configured properly when the unit leaves the factory. The
information in this section is provided merely for reference.

2.5.1 Shelf connections


The shelves of the PS1UDC+ system are interconnected. Each type-2 shelf (shelves for rectifiers
only) contains two connectors, labeled P1 and P3. The P1 connector is connected to the shelf
above it, the P3 connector is connected to the shelf below it.

The type-1 shelf (which contains the controller) has only one connector, labeled P1. It is
connected to P1 on the shelf below it.

The shelf interconnections are shown in Figure 5 below.

Figure 5: Shelf connections and jumpers on system rear side

2.5.2 Jumpers
Each shelf has jumpers. Proper setting of these jumpers is required to ensure correct assignment
of the correct addresses to each rectifier for controller indications.

The type-1 shelf (shelf that includes a controller) has one jumper, labeled J1. If the system
includes a controller, the type-1 shelf must always be the top (or only) shelf.

The type-2 shelf (shelf for rectifiers only) has three jumpers, labeled J1, J2, and J3.

The location of the jumpers on the rear side of the shelves is shown in Figure 5 above. The
proper setting of these jumpers depends on the number and type of shelves in the system, and is
shown in Table 2 below.

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Table 2: Jumper settings for system shelves


JUMPERS TO BE CONNECTED
SHELF POSITION
(“SHORTED”)
Top shelf (if type-1) but not only shelf None
Top shelf (if type-2) but not only shelf J2
Middle (not top and not bottom) J1
Bottom (but not the only shelf) J1, J3
Only shelf and it is type-2 J2, J3
Only shelf and it is type-1 J1

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3. THE RECTIFIER MODULE


The rectifier module is the heart of the full-redundancy power system. It is a plug-in module
designed specifically for modular systems. The power factor correction (PFC) device at the input
enables clean, harmonic-free, sinusoidal current consumption from the ac input. The power factor
corrector produces a 400 Vdc output, which is then down-converted to the 48 Vdc output voltage.

A current sharing circuit is responsible for accurate current sharing among the rectifiers. This
enables each one of the rectifiers to change its output voltage slightly until sharing is achieved.

The output current is indicated by the 4-LED bar graph on the left side of the front panel shown
on the front panel (see Figure 6). This bar graph is used to verify the current sharing operation,
as well as to indicate the percentage of the full load.

Figure 6: Rectifier LED bar-graph of load

The rectifier module requires forced cooling. The speed of the fan used for evacuating the heat
from internal components is variable. A special circuit changes the speed of the fan according to
the load level. This prolongs the life of the fan, thus increasing the MTBF of the rectifier module
itself. Other benefits include reduced audible noise and induced internal dust deposits.

3.1 Simplified block diagram of a rectifier module

Figure 7: Block diagram of a rectifier module

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3.2 Views of a rectifier module

Figure 8: Views of a rectifier module

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3.3 Rear panel of a rectifier

Figure 9: Rear panel of a rectifier module

Table 3 describes the functions of the pins on the rear panel of a rectifier module.
Table 3: Pin assignments on rectifier module rear panel
PIN # NAME DESCRIPTION SIGNAL LEVEL
32 PE Protective earth (Ground) 0V
30 Phase Ac input phase 85-270 Vac (referenced to N)
28 Tx Transmit communication output signal 0 – 2 mA (floating open collector)
26 Neutral Input ac neutral ---
24 SHR Current sharing bus 0 – 3.3 V (referenced to –Vout)
22 Rx Receive communication input signal 0 – 5 V (referenced to COMM)
20 ADRESS2 Analog input for module address 0 – 5 V (referenced to –Vout)
18 COMM Common port of communication 0V
16 ADRESS1 Analog input for module address 0 – 5 V (referenced to –Vout)
14 +Vout Dc output positive 48 or 24 Vdc (referenced to –Vout)
12 -Vout Dc output negative 0V
10 +Vout Dc output positive 48 or 24 Vdc (referenced to –Vout)
8 -Vout Dc output negative 0V
6 +Vout Dc output positive 48 or 24 Vdc (referenced to –Vout)
4 -Vout Dc output negative 0V

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3.4 Rectifier calibration


Calibration of the PFC module is simple and involves a single trimmer, which adjusts the output
voltage.

To calibrate the rectifier:


1. Connect the rectifier to the ac input.
2. Access the trimmer (see Figure 10) via the small opening at the top of the cover.
3. Using a voltmeter, set the output voltage to 54 Vdc (48 Vdc module)
or 27 Vdc (24 Vdc module).

Note: Other voltages are possible. Please consult Gamatronic's specialists for information
regarding specific models.

Figure 10: Rectifier calibration point

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4. TECHNICAL SPECIFICATIONS
This chapter contains the technical specifications for the two types of the PS1UDC+ system and
the associated rectifier model.

Section 4.1 contains the specifications for the standard PS1UDC+ system.

Section 4.2 contains the specifications for the standard PS1UDC+ rectifier module.

Section 4.3 contains the specifications for the PS1UDC+ LLC system.

Section 4.4 contains the specifications for the PS1UDC+ LLC rectifier module.

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4.1 Technical specifications for the standard PS1UDC+ system


INPUT
Nominal voltage 185 to 275 VAC
Permitted variation 85 to 300 VAC
1
Maximum current (at full load) N*10A
Frequency 47 to 63 Hz
Power factor (at full load) ≥ 0.99
OUTPUT
Maximum configuration 38 rectifier modules + controller, (1255 A, 54 v, 68.4 kW)
Voltage (default) 54 ±0.2 VDC
Adjustable range 47 to 58 VDC
Regulation (line & load) ±0.25 V
1 N*33 A (Vin>200 VAC)
Nominal Current
N*16 A (Vin=110 VAC)
Ripple & noise @ BW=30 MHz 200 mV p-p, 40 mVrms
Psophometric noise -52 dbm over 600 Ώ (<2 mV)
Efficiency 92 % @ 230 VAC
(nominal load) 88 % @ 110 VAC
1
Overload current N*35 A (Vin>200 VAC)
(Short circuit current, Vo=0) <N*14 A (Vin=230 VAC)
Over-voltage protection 59.5 V
Walk-in time 30 s
Hold-up time (fully loaded) 10 ms
Output current indication Alpha-numeric LCD on the system controller, 4 LEDs on each module
Active current sharing ±10 % accuracy at full load
GENERAL
2
System controller Full status monitoring and communication with a PC, dedicated GUI, USB
3
Withstand voltage (1 min) 3000 VAC INPUT/OUTPUT, 1500 VAC INPUT/GND, 700 VDC OUTPUT/GND
Operating temperature -10 to 75 °C (output de-rated at >50 °C by 4 % / °C)
Humidity <95% non-condensing, equipped with standard PS1UDC+ rack
Storage temperature -20 to 80 °C
EMC EN 300 386-2 V1.1.3 (1997), EN55022, EN 6100 –4-2,3,4,5,6,11 EN 61000-3-2 and EN 61000-3-3
Safety Conforms to IEC950, EN60950
Dimensions Sub-rack 19”(W) x 1U(H) x 320 mm(D) w/o terminals (360 mm with terminals)
Rectifier module 146 mm (W) x 44 mm (H) x 260 mm (D)
1
Weight (Kg) Sub-rack (N*1.2 kg)+4.2 kg (fully equipped system – max. 10.2 kg)
Rectifier module 1.2 kg
ELVD
Max. current withstand 2x70 ADC or 1x120 AAC
Notes:
1. N=number of modules 3. Equivalent dc test voltage is applied to overcome Y-capacitors' leakage current to ground. Output is floating (not grounded) during test.
2. The basic shelf has a system controller.

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4.2 Specifications for the standard PS1UDC+ rectifier module


INPUT
Nominal voltage 185 to 275 VAC
Permitted variation 85 to 300 VAC
Maximum current (at full load) 10 A
Frequency 47 to 63 Hz
Power factor (at full load) ≥ 0.99
OUTPUT
Voltage (default) 54 ±0.2 VDC
Adjustable range 47 to 58 VDC
1
Regulation (line & load) ± 1 % standalone, ±0.5 % in system operation
1 33 A (Vin>200 VAC)
Nominal Current
16 A (Vin=110 VAC)
Ripple & noise @ BW=30MHz 200 mV p-p, 40 mVrms
Psophometric noise -52 dbm over 600 Ώ (<2 mV)
Efficiency 92 % @ 230 VAC
(nominal load) 88 % @ 110 VAC
Overload current 35 A (Vin>200 VAC)
(Short circuit current, Vo=0) 14 A (Vin=230 VAC)
2
Over-voltage protection 59.5 V
Walk-in time 10 s
Hold-up time (fully loaded) 10 ms
Output current indication 4 LEDs bar-graph on the front panel
Active current sharing ±10 % accuracy at full load
GENERAL
3
Withstand voltage (1 min) 3000 VAC INPUT/OUTPUT, 1500 VAC INPUT/GND, 1000 VDC OUTPUT/GND
Operating temperature -10 to 75 °C (output de-rated at >50 °C by 4 % / °C)
Humidity <95 % non-condensing, equipped with standard PS1UDC+ rack
Storage temperature -20 to 80 °C
EMC EN 300 386-2 V1.1.3 (1997), EN55022, EN 6100 –4-2,3,4,5,6,11 EN 61000-3-2 and EN 61000-3-3
Safety Conforms to IEC950, EN60950
Dimensions 146 mm (W) x 44 mm (H) x 260 mm (D)
Weight (Kg) 1.2 kg
Notes:
3. Equivalent dc test voltage is applied to overcome Y-capacitors' leakage current to ground.
1. Shared bus is grounded and disabled, single rectifier test.
Output is floating (not grounded during test).
2. Hiccup operation mode.

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4.3 Technical specifications for the PS1UDC+ LLC system


MODEL  24 VDC MODEL 48 VDC MODEL
INPUT
Nominal voltage 185 to 275 VAC
Permitted variation 85 to 300 VAC
1
Maximum current (at full load) N*6 A N*10 A
Frequency 47 to 63 Hz
Power factor (at full load) ≥ 0.99
OUTPUT
Maximum configuration 38 rectifier modules + controller, (1520 A, 27 V, 41 kW) 38 rectifier modules + controller, (1255 A, 54 V, 68.4 kW)
Voltage (default) 27 ±0.1 VDC 54 ±0.2 VDC
Adjustable range 21 to 29 VDC 42 to 58 VDC
Regulation (line & load) ±0.5 %; ±0.25 % with controller
1 N*40 A (Vin>195 VAC) N*33.3 A (Vin>195 VAC)
Nominal Current
N*20 A (Vin=110 VAC) N*16 A (Vin=110 VAC)
Ripple & noise @ BW=30 MHz 150 mV p-p, 30 mVrms 200 mV p-p, 40 mVrms
Psophometric noise -52 dbm over 600 Ώ (<2 mV)
Efficiency: (nominal load) up to 93 % up to 95.2 %
(50 % load) up to 94.2 % up to 96.2 %
1
Overload current N*42 A (Vin>200 VAC) N*35 A (Vin>200 VAC)
(Short circuit current, Vo=0) <N*20 A (Vin=230 VAC) <N*20 A (Vin=230 VAC)
Over-voltage protection 30 V 59.5 V
Walk-in time 10 s
Hold-up time @ nominal input ≥ 20 ms (90% load, output decays to 23 V) 20 ms (90% load, output decays to 46 V)
Output current indication Alpha-numeric LCD on the system controller, 4 LEDs on each module
Active current sharing ±10 % accuracy at full load
GENERAL
2
System controller Full status monitoring and communication with a PC, dedicated GUI, USB, RJ45
3
Withstand voltage (1 min) 3000 VAC INPUT/OUTPUT, 1500 VAC INPUT/GND
Operating temperature -10 to 75 °C (output de-rated at >50 °C by 4 % / °C)
Humidity <95 % non-condensing, equipped with standard PS1UDC+ rack
Storage temperature -20 ~ 80 °C
EMC ETSI, EN 300 386 V1.5.1 (2010-05), EN 55022 Class B, EN 61000-4-2/3/4/5/6/11, EN 61000-3-2 and EN 61000-3-3
Safety Conforms to IEC 90650
Dimensions Sub-rack 19” (W) x 1U (H) x 320 mm (D) w/o terminals (360 mm with terminals)
Rectifier module 146 mm (W) x 44 mm (H) x 260 mm (D)
1
Weight (Kg) Sub-rack (N*1.4 kg)+4.2 kg (fully equipped system – max. 11.2 kg)
Rectifier module 1.4 kg
ELVD
Max. current withstand 2x70 ADC or 1x120 AAC
Notes:
1. N=number of modules 3. Equivalent dc test voltage is applied to overcome Y-capacitors' leakage current to ground. Output is floating (not grounded) during test.
2. The basic shelf has a system controller.

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4.4 Specifications for the PS1UDC+ LLC rectifier module


MODEL  24 VDC MODULE 48 VDC MODULE
INPUT
Nominal voltage 185 to 275 VAC
Permitted variation 85 to 300 VAC
Maximum current (at full load) 6A 10 A
Frequency 47 to 63 Hz
Power factor (at full load) ≥ 0.99
OUTPUT
Voltage (default) 27 ±0.1 VDC 54 ±0.2 VDC
Adjustable range 21 to 29 VDC 42 to 58 VDC
1
Regulation (line & load) ±0.5 %; ±0.25 % when operating with controller
1 40 A (Vin>195 VAC) 33.3 A (Vin>195 VAC)
Nominal Current
20 A (Vin=110 VAC) 16 A (Vin=110 VAC)
Ripple & noise @ BW=30MHz 150 mV p-p, 30 mVrms 200 mV p-p, 40 mVrms
Psophometric noise -52 dbm over 600 Ώ (<2 mV)
Efficiency: (nominal load) up to 93 % up to 95.2 %
(50 % load) up to 94.2 % up to 96.2 %
Overload current 42 A (Vin>200 VAC) 35 A (Vin>200 VAC)
(Short circuit current, Vo=0) 20 A (Vin=230 VAC) 20 A (Vin=230 VAC)
2
Over-voltage protection 30 V 59.5 V
Walk-in time 10 s 10 s
Hold-up time @ nominal input ≥ 20 ms (90 % load, output decays to 23 V) 20 ms (90 % load, output decays to 46 V)
Output current indication 4 LEDs bar-graph on the front panel
Active current sharing ±10 % accuracy at full load
GENERAL
3
Withstand voltage (1 min) 3000 VAC INPUT/OUTPUT, 1500 VAC INPUT/GND
Operating temperature -10 to 75 °C (output de-rated at >50 °C by 4 % / °C)
Humidity <95 % non-condensing, equipped with standard PS1UDC+ rack
Storage temperature -20 to 80 °C
EMC ETSI, EN 300 386 V1.5.1 (2010-05), EN 55022 Class B, EN 61000-4-2/3/4/5/6/11, EN 61000-3-2 and EN 61000-3-3
Safety IEC 60950
Dimensions 146 mm (W) x 44 mm (H) x 260 mm (D)
Weight (Kg) 1.4 kg
Notes:
3. Equivalent dc test voltage is applied to overcome Y-capacitors' leakage current to ground.
1. Shared bus is grounded and disabled, single rectifier test.
Output is floating (not grounded during test).
2. Hiccup operation mode.

Dc power system model PS1UDC+ Technical specifications 15


User Guide Gamatronic Electronic Industries Ltd.

5. SYSTEM CONTROLLER SC1UDC+


The PS1UDC+ system includes a system controller called the SC1UDC+. The SC1UDC+
controller is shown in Figure 11.

A comprehensive description of the controller is provided in a separate manual (titled Dc Power


System Controller Model SC1UDC+).

The SC1UDC+ system controller is 1U in height and is located on the top shelf of the system.
The controller monitors and controls all of the system components: the rectifiers (up to 38
modules), the LVD, the battery strings. The controller is hot-plugged, which means it can be slid
into or out of the system while the system is operating, without affecting the supply of power to
the load devices.

The front panel of the controller includes two connections for communication – a USB socket and
an Ethernet socket. The controller's electrical connections to the power system are on its rear
panel.

The SC1UDC+ controller is designed to be used with an external PC monitor, so the number of
function buttons and indicator LEDs on the front panel are limited. The controller also has an
audible alarm.

The controller includes an LCD screen on which can be displayed a wide range of system
measurements and parameters.

The SC1UDC+ system controller regulates the system’s dc output voltage by measuring and
correcting it in a negative feedback loop. This ensures a 0.5% absolute error in all conditions.

When the SC1UDC+ system controller module is not present or is removed, the PS1UDC+
system maintains its output at the user-determined default voltage level, with no interruption of
the voltage supplied to the load or batteries.

Two versions of the SC1UDC+ system controller are available:

• Standard version: RS232 serial communication


• NET version: includes both RS232 serial communication and SNMP/TCP/IP communication

Note: The standard version can be upgraded to the NET version. Check your SC1UDC+ manual
for details.

Figure 11: System controller SC1UDC+

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5.1 Controller front panel


The SC1UDC+ front panel is shown in Figure 12.

Figure 12: Front panel of system controller SC1UDC+

5.1.1 Front panel features:


• Ethernet socket: for remote monitoring over an Ethernet network (TCP/IP)
• USB type B socket: for direct connection of the controller to a computer using a USB-USB
cable. This enables the use of a graphic software interface to monitor and control the power
system from the computer. For details, see the user guide for the SC1UDC+ controller.
• Indicator LEDs: see Table 4 below.
• LCD display screen: Displays system status, parameter settings, voltage, current,
temperature readings. Used together with the buttons, enables the user to set system
parameters.
• Five function buttons: (see Table 5 below).
• Lock tab: Locks the controller in place in the cabinet; pressing down on the lock tab releases
the controller from the cabinet.
• Audible alarm: Warns of faults in the system.

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5.1.1.1 LED Indicator lights

Table 4: LED indicator lights

LED DESCRIPTION

• Steady on = Normal input voltage from the mains.


AC
(green) • Unlit = AC input voltage is absent or out of range.

• Steady on = Dc floating voltage is normal.


DC
• Unlit = Fault in the dc floating voltage.
(green)
• Flashing = Equalizing mode is in effect.

RECT • Lit = One or more rectifiers are faulty.

(red) • Unlit = Rectifiers are operating normally.

• Steady on = Command has been issued to open the ELVD (command was
LVD issued either by the system or by the user).
(red)
• Unlit = normal operation mode.

• Steady on = Last battery test was passed.


BATT • Blinking = Battery test in progress.
(green)
• Unlit = Last battery test failed.

• Blinking = unconfirmed fault in the system.


ALARM • Steady on = Most recent alarms have been acknowledged by the operator.
(red)
• Unlit = No active faults.

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5.1.1.2 Navigation keys


The following table describes the results of pressing each of the navigation keys:
Table 5: Function buttons on the front panel

BUTTON FUNCTION

Scroll up / Increase displayed value


(function depends on context)

Scroll down / Decrease displayed value


(function depends on context)

Scroll right. When the “end” of the data is reached, the scrolling wraps around
to the beginning of the data again.

Select a menu option / Save user-entered values.

• Exit from the current function or menu.


• Pressing this key on the default display screen when an alarm condition is
active silences the audible alarm, confirms the alarm, and changes the
alarm LED mode from flashing to steady on. A fresh alarm reactivates the
audible alarm and returns the alarm LED to blinking mode.

5.1.1.3 Audible alarm buzzer


The audible alarm buzzer warns users of the existence of a fault or faults in the power system.
The Alarm LED remains lit as long as there is an active fault, even if the alarm buzzer has
stopped or has been silenced via the ESC key.

When a fault occurs, the alarm sounds until either the ESC button is pressed or the fault is
corrected. Note that the maximum audible alarm time can be limited to 15 seconds by a user-
configurable controller setting (Main menu > Advanced > Buzzer Duration).

5.1.1.4 USB socket


This port enables RS232 communication between the controller and a directly connected
computer, over a USB-USB cable. Enables use of a graphic software interface for monitoring and
control of system operation, status, and parameter settings. For details, see the user guide for the
SC1UDC+ system controller.

5.1.1.5 Ethernet (RJ45) socket


This port enables remote communication over an Ethernet network using the SNMP/TCP/IP
protocol, allowing remote monitoring and control of system operation, status, and parameter
settings via a graphic software interface. For details, see the user guide for the SC1UDC+ system
controller.

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User Guide Gamatronic Electronic Industries Ltd.

5.2 Battery test


Both batteries are automatically tested on a periodic basis by the system controller. The length of
time between tests can be modified by the user.

Manual ("on-demand") battery tests can also be performed.

The battery is tested by lowering the rectifier’s dc voltage to a preset level for a user-definable
duration, and simultaneously measuring the battery voltage and current through the load during
battery discharge. During the battery test, the battery LED on the controller blinks on and off.

If the battery is efficient and fully charged, the voltage reading remains above a specific, user-
defined threshold for the duration of the test, and "passes" the battery test. The controller's
Battery LED moves to a steady "ON" state.

If the battery is inefficient or weak, the voltage reading will fall below the user-defined threshold
and a “battery test failed” alarm is generated. In this case the battery LED on the controller
remains in a steady “OFF” state after the battery test.

When the PS1UDC+ system is managing two battery sets, the battery test proceeds as follows:

1. The voltage of the two battery sets are tested in parallel. If the measured voltage is
below the user-defined threshold, a “battery test failed” alarm is generated and the
battery LED on the controller remains in a steady “OFF” state after the battery test.
2. If the battery sets passed the voltage test, the current of one battery set is compared to
the other. If the current produced by one battery set is significantly lower than the current
of the other battery set, the set with the lower current is considered unsatisfactory, a
“battery test failed” alarm is generated and the battery LED on the controller remains in a
steady “on” state after the battery test. A console function on the controller enables the
user to determine which of the battery sets is unsatisfactory.

The battery LED on the controller moves to a steady “ON” state if the status of both battery sets is
normal.

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5.3 Rectifier addresses


The rectifier modules are in constant communication with the controller, reporting their status and
receiving commands to perform any needed load adjustments. To ensure proper routing of
communications between the rectifiers and the controller, each rectifier is assigned an ID based
on its location (row or shelf number and column number).

Figure 13 shows the address assignments for a system with 38 rectifiers and a controller. Note
that if a system includes a controller it must be located in the upper right slot, when viewed from
the front of the system.

Figure 13: Address assignments for 38 rectifiers with controller

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6. ELVD (ELECTRONIC LOW-VOLTAGE DISCONNECT DEVICE)


The ELVD (Electronic Low-Voltage Disconnect device) is connected to the “frame motherboard”
(a special motherboard for the controller and top row rectifiers) and can be accessed from the
rear of the system after removing the rear metal cover.

The device, which contains dual 70 A ELVDs mounted on one board, can control the
disconnection of two separate battery sets. Alternatively, the ELVDs can be connected in parallel
to a single 120 A output. (For higher battery current ratings a special additional contactor (LVD)
can be provided.)

The ELVD disconnects the battery set(s) from the load when the output voltage falls below a
user-specified value (i.e., when the battery is deeply discharged), thus protecting the battery from
permanent damage due to over-discharge.

The ELVD in the PS1UDC+ system uses power MOSFETs for switching. (These solid-state
devices replace the traditional electromechanical relays and contactors and have a higher
MTBF.)

The ELVD can be easily replaced, if necessary.

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7. INSTALLATION PROCEDURES
7.1 Safety instructions
ATTENTION
Read the following safety information carefully before using this power supply
CAUTION identifies conditions and actions that may damage the power supply.
WARNING identifies conditions and actions that expose the user to hazard(s).

• WARNING – Installation and servicing of the PS1UDC+ system and its components shall be
performed only by qualified, trained personnel.
• WARNING - Restricted Access Location: This power system shall be installed in the supplied
cabinet only. The cabinet provides a fire and electrical enclosure for the system and also
enhances EMI/RFI performance. Safety standards are applicable to this unit providing that it
is enclosed in a prescribed cabinet.
• WARNING - This power supply must be grounded to protective earth (PE).
The unit receives the PE connection from the power cord and from the rack itself.
• WARNING - Do not allow any object to be inserted into the unit through the ventilation holes.
• WARNING - Do not allow any liquids to get into the unit through the ventilation holes.
• WARNING - Always turn OFF power switch and the battery circuit breaker, and detach the ac
cord from the power mains before removing the rear cover of the cabinet.
• WARNING - Danger of electrical shock exists for several minutes after unplugging the system
from the mains.
• CAUTION – Do not block the ventilation holes. This may cause a high temperature rise in the
unit and, as a result, damage it or shorten its life.
• CAUTION – Each rectifier module uses DOUBLE POLE/NEUTRAL FUSING.
• WARNING – While replacing fuses in the rectifier modules always use the same type and
rating as the original fuse: 10 A / 250 V, DOUBLE POLE/NEUTRAL FUSING.

7.2 General
The system should be wired to the load(s) and battery set(s). See Figure 4 and Table 1 on
page 4.

In order to gain access to the motherboard terminals, the rear cover must first be removed.

The ac line input is 3-phase, although for small, low-load systems it is also possible to use single-
phase input.

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7.3 Fuses
• CAUTION – Each rectifier module uses DOUBLE POLE/NEUTRAL FUSING.
• WARNING – While replacing fuses in the rectifier modules always use the same type and
rating as the original fuse: 10 A / 250 V, DOUBLE POLE/NEUTRAL FUSING.

7.4 Installing the system


1. Verify that the load, battery and line input’s circuit breakers are disconnected. Access
the internal connections by carefully opening the rear cover.
2. Connect the battery and the load to the system via the battery and load terminals on the
rear panel (see Figure 4 on page 4) and refasten the rear cover with its screws.
3. Verify that the ac input is properly connected to each shelf (See item 5 in Figure 4).
4. Plug the ac input cord into the mains.
5. Turn on the line circuit breaker and verify that the modules’ LEDs are activated. Verify
that the system controller's LEDs and display screen are activated.
6. Install the supplied GUI software on your PC.
7. Connect the communication cable from the controller’s RS232 terminal to the PC. The
GUI should indicate normal communications and measurements.
8. Verify that no red LEDs are lit.
9. Switch on the load and battery circuit breakers.
10. The system is ready for use.
11. Use the software to change the system’s settings (e.g. float/boost charging voltage) if
necessary.

7.5 Output dry contacts


The system also provides six floating output signals for system status indication and alarm
transmission (in addition to the data provided by the controller via the RS232 terminal).

These six output signals are accessible via output dry contact connections on the motherboard.

The output dry contacts are assignable to a variety of system events and their behavior can be
defined through the software. Refer to the SC1UDC+ controller documentation for details.

The dry contacts connections are located in a single component, labeled P13 on the motherboard
and are shown in Figure 11:

These dry contacts are Normally Open, and close when the designated system event occurs.
Ratings for the dry contacts 1–6 are 60 V / 1 A maximum. Each dry contact can be set to be
normally closed during controller manufacturing.

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Figure 11: Output dry contacts

Table 6 below details the factory-default assingment of alarms to the output dry contacts. These defaults
can be changed by the user using the supplied graphic interface software.

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Table 6: Factory std. assgnmnt of syst. alarms to output dry contacts

OUTPUT DRY CONTACT #


ALARM # ALARM DESCRIPTION
1 2 3 4 5 6
1 X X AC input voltage HIGH.
2 X X AC input voltage LOW.
3 X X DC voltage LOW LOW – Boost (equalizing) or floating (see Figure 14 below).
4 X X DC voltage LOW – Boost (equalizing) or floating (see Figure 14 below).
5 X X DC voltage HIGH – Boost (equalizing) or floating (see Figure 14 below).
6 X X Battery circuit breaker is OPEN (via input dry contact #1).
7 X Battery temperature exceeds maximum.
8 X X X Last battery test failed (non-volatile message).
9 X LVD open (via input dry contact #4).
10 X X User input dry contact is OPEN (via input dry contact #5).
11 X X X Communication with rectifier(s) – No response.
12 X X LVD forced OPEN command issued.
13 -UNUSED-
14 X X One or more load circuit breakers are open (via input dry contact #2).
15 -UNUSED-
16 X AC input surge has blown a surge protector (via input dry contact #3).
17 X X Battery test time-stamp.
18 X X X Equalize test time-stamp.
DC voltage HIGH HIGH (see Figure 14 below) –
19 X X
switches OFF rectifier modules one by one until DC within normal range.
20 X Overload.
21 X User input dry contact is open (via input dry contact #6).
22 X User input dry contact is open (via input dry contact #7).
23 X User input dry contact is open (via input dry contact #8).
24 -UNUSED-
25 -UNUSED-
26 X Communication with converter(s) – No response
27 X Converter high voltage
28 X Converter low voltage
29 X More than one rectifier fault
30 -UNUSED-
31 X X Controller time-stamp.
32 -UNUSED-

Figure 14: Relative dc voltage levels

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7.6 Input dry contacts


Connector P14 on the system motherboard contains connections to eight input dry contacts.
These inputs can be used to accept signals from other, external equipment. A signal consists of a
change in the state of the external circuit connected to the input dry contacts. The external circuit
can be in either of two states: open or closed. The user can observe the status of each of the
input dry contacts (open or closed) via the graphic user interface software.

The input dry contacts can be used, for example, to monitor the state of critical system circuit
breakers such as the ac input circuit breaker, the battery circuit breaker, load circuit breakers.
A dry contact can be used to monitor the state of the lightning protection.

The input dry contacts can be used to monitor the state of other equipment, such as a smoke
detector or a circuit to detect the opening of a door or the operation of an air conditioner.

To connect an exterior circuit to the input dry contacts, connect one side of the circuit to any of
pins 1 through 8, and the other side of the circuit to either pin 9 or 10 – there is no electrical
difference between pins 9 and 10

Note: The circuit connected to the input dry contacts must be voltage free at all times. The
presence of voltage on the external circuit may damage the controller and/or prevent the
system from detecting a change in state of the circuit.

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7.7 Battery temperature compensation


To ensure optimum charging voltage, the PS1UDC+ varies the battery charging voltage
according to the battery temperature, as measured by the system controller and two temperature
sensors.

The calculated temperature is the average of the two measurements. In case one sensor is
absent or defective, the system will ignore this sensor and treat the normal sensor only. The
temperature value is displayed on the PC screen and is used to calculate the compensation. The
compensation coefficient is negative and is programmable by the software. Typical compensation
value is [–3 mV/°C] per 2-V VRLA cell.

The temperature sensors are of the RTD type and their connections, are labeled “P5” on the
motherboard.

Figure 15: Connections for battery temperature sensors

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8. COMPUTATIONS
This section explains how to determine the battery capacity required by the system, and how to
compute number of rectifier modules needed to satisfy the power required by the load and for
battery charging.

The battery's function is to supply sufficient power to power the load in the event of a failure of the
power system's ac input source. When the ac input is restored, the system recharges the battery.
At that time, the rectifiers must supply sufficient power to supply the maximum load and to charge
the battery.

8.1.1 Computing required battery capacity


The formula for computing the battery capacity (BATTCAPAC) required for the system is:

BATCAPAC [in Ah] = (TBACKUP * ILOAD), where:


TBACKUP is the backup time (in hours) that the batteries must supply, and
ILOAD = maximum current required by load [in amperes].

Example (for 48 Vdc system):

Assume that the requirement for battery backup time is 8 hours, so: TBACKUP = 8 hours.
Assume that the load current is 60 A at 48 V. This means ILOAD = 60.
The required battery capacity is TBACKUP * ILOAD = 8 hr. x 60 A = 480 Ah.

A backup capacity of 480 Ah / 48 V can be supplied by a bank of four 480 Ah / 12 V batteries


connected in series.

8.1.2 Computing required battery recharge current


The formula for computing the required battery recharge current is:

IRECHARGE = BATCAPAC * 1.15 / TRECHARGE, where


BATCAPAC is battery capacity as computed above,
1.15 is a safety factor to ensure sufficient current, and
TRECHARGE = time (hrs) needed to recharge the battery (according to batt. mfr.'s specs)

Example (for 48 Vdc system):

Assume battery capacity is 480 Ah / 48 V as computed in the previous example.


Assume battery recharge time is 20 hrs as per the battery manufacturer's specification sheet.

The required battery recharge current is (480 Ah * 1.15) / 20 = 27.6 A

8.1.3 Computing the number of rectifier modules required


To compute the number of rectifier modules required it is first necessary to compute the total
current (ITOTAL) required to simultaneously supply the maximum load and charge the batteries.

ITOTAL = ILOAD + IRECHARGE, where


ILOAD is maximum load current, and
IRECHARGE is the required battery recharge current as computed above.

Continuing with our example from above, ILOAD = 60 A and IRECHARGE = 27.6 A, so the
33 A / 48 V rectifiers must provide a total (ITOTAL) of 87.6 A.

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To find the number of rectifiers required, divide ITOTAL by 33 A, which is the maximum output of
a single rectifier module. If there is a remainder, round up to the next whole number. To provide
N+1 redundancy to the system, add 1 to the result.

Example:

87.6 / 33 = 2.63 ≈ 3 for our purposes, so a minimum of 3 rectifier modules are needed.
To provide N+1 redundancy, 4 modules are needed.

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9. TROUBLESHOOTING
The table below summarizes the most frequently encountered problem conditions and suggests
possible solutions for them. Refer to this table before calling for service.

SYMPTOM POSSIBLE CAUSE REMEDY

Ac LED (on the


No ac input. Check that the line MCB is on.
controller) is OFF.

Dc LED (on the Check that the system is connected to


Output voltage is too low.
controller) is OFF. the mains.

There was a prolonged ac


Verify that the ac input circuit breaker is
outage and the batteries have
LVD LED is steady ON.
become discharged.
ON.
The output dc voltage is too Verify that the system is connected to the
low. ac input.

Battery is not connected. Check battery cables and circuit breaker.

No backup time when Battery was disconnected by


ac is absent LVD. (LVD LED is lit, battery is When the ac input returns, allow the
discharged to "LOW LOW" battery time to recharge.
level.

Check load cables.


Load is not operating Load is not connected.
Check load circuit breaker.

No current sharing Load is too high (rectifiers are Decrease the load or add rectifiers to the
among rectifiers in current-limit mode). system.
(more then 1 LEDs
difference between Rectifier(s) output voltages are Recalibrate the voltage of the problematic
any two modules). not properly adjusted. rectifier(s).

Battery is too small for the


Increase battery capacity.
application.
Check the system output voltage from the
Charging voltage is too low.
connected PC or the controller console.

Use the equalize (boost) charging feature


Battery backup time to quickly charge the battery. .
is too low

Weak battery. Verify that ambient temperature is


acceptable as per the battery
manufacturer's specifications.

If the battery is old or you suspect it to be


defective, replace it

Dc power system model PS1UDC+ Troubleshooting 31

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