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MODEL PS1UDC+
USER GUIDE
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
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majeure.
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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.
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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.
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purposes other than those for which it was disclosed is strictly forbidden.
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Information supplied by Gamatronic is believed to be accurate and reliable. However, no responsibility is assumed by Gamatronic for
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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
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notify Gamatronic Electronic Industries Ltd. All specifications are subject to change without prior notice.
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
LIST OF FIGURES
LIST OF TABLES
Table 6: Factory std. assgnmnt of syst. alarms to output dry contacts ........................... 26
U U
1. INTRODUCTION
The Gamatronic "PS1UDC+" power system:
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.
The 48 Vdc power system can use one of two types of rectifier modules:
The 24 Vdc power system accepts only the LLC type of rectifier module,
with efficiency of up to 94 % for Vin=230 Vac.
2. SYSTEM DESCRIPTION
2.1 Overview
The PS1UDC+ power system is comprised of four main subsystems:
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.
• Maximum current rating of the power system is 1250 A. Actual rating depends on the number
of rectifier modules.
• 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.
• 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.
• 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).
The connections and jumpers are configured properly when the unit leaves the factory. The
information in this section is provided merely for reference.
The type-1 shelf (which contains the controller) has only one connector, labeled P1. It is
connected to P1 on the shelf below it.
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.
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.
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.
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
Note: Other voltages are possible. Please consult Gamatronic's specialists for information
regarding specific models.
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.
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.
Note: The standard version can be upgraded to the NET version. Check your SC1UDC+ manual
for details.
LED DESCRIPTION
• 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.
BUTTON FUNCTION
Scroll right. When the “end” of the data is reached, the scrolling wraps around
to the beginning of the data again.
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).
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.
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.
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.)
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).