Power System Controller: Model SC2012U Universal

Gamatronic Electronic Industries Ltd.
POWER SYSTEM CONTROLLER

MODEL SC2012U UNIVERSAL
User Guide and Instruction Manual
Release 1.1
February 2006
Har Hotzvim Industrial Park,

14 Hartom St., PO Box 45029, Jerusalem 97774, Israel
Tel: +972-2-588-8222 Fax: +972-2-582-8875
Email: info@gamatronic.co.il web: www.gamatronic.com
2MUH2012U
User Guide Gamatronic Electronic Industries Ltd.
Gamatronic Electronic Industries Ltd.

Har Hotzvim Industrial Park
14 Hartom St.
PO Box 45029
Jerusalem 97774
Israel
Tel: +972-2-588-8222
Fax: +972-2-582-8875
Email: info@gamatronic.co.il
Website: www.gamatronic.com
© Copyright 2006 by Gamatronic Electronic Industries Ltd. All rights reserved worldwide.
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 Electronic Industries
Ltd. rights in the aforesaid information. Neither this document nor the information contained herein may be published,
or reproduced, in whole or in part, without the express, prior, written permission of Gamatronic Electronic Industries
Ltd. 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 Electronic Industries Ltd. reserves the right, without prior notice or liability, to make changes in
equipment design or specifications.
Information supplied by Gamatronic Electronic Industries Ltd. is believed to be accurate and reliable. However, no
responsibility is assumed by Gamatronic Electronic Industries Ltd. for the use thereof nor for the rights of third
parties which may be effected in any way by the use thereof.
Any representation(s) in this document concerning performance of Gamatronic Electronic Industries Ltd.
product(s) are for informational purposes only and are not warranties of future performance, either express or implied.
Gamatronic Electronic Industries Ltd. standard limited warranty, available upon request, stated in its sales contract
or order confirmation form, is the only warranty offered by Gamatronic Electronic Industries Ltd. in relation thereto.
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.
ii User Guide and Instruction Manual Gamatronic Electronic Industries Ltd.

Gamatronic Electronic Industries Ltd. User Guide
TABLE OF CONTENTS
1. INTRODUCTION.................................................................................................... 1
1.1 SC2012U’s Main Features............................................................................ 1
2. SYSTEM CONTROLLER ....................................................................................... 3
2.1 Front Panel ................................................................................................... 3
2.1.1 LCD Panel Display ........................................................................ 3
2.1.2 LED Status Indicators.................................................................... 3
2.1.3 Navigation Keys............................................................................. 5
2.1.4 Audible alarm buzzer..................................................................... 5
2.1.5 DB9 Serial Port.............................................................................. 5
2.2 RS232 Communication Protocol & Data Structure ....................................... 5
2.2.1 General Information....................................................................... 5
2.2.2 Master............................................................................................ 6
2.2.3 Slave.............................................................................................. 7
3. THEORY OF OPERATION .................................................................................... 8
3.1 PD Bus Communication................................................................................ 8
3.2 Charge Modes .............................................................................................. 8
3.2.1 Floating Mode................................................................................ 9
3.2.2 Equalizing Mode ............................................................................ 9
3.2.3 Battery Charging Current Limit ...................................................... 9
3.3 Battery Test .................................................................................................. 9
3.4 Rectifiers and Converters Current Sharing ................................................. 10
3.5 User Modifications to Set Nominal Values.................................................. 10
3.5.1 Output Voltage............................................................................. 10
3.5.2 Battery Test ................................................................................. 11
3.5.3 Battery Charge Temperature Compensation............................... 11
3.5.4 LVD.............................................................................................. 12
3.5.5 Alarm Thresholds ........................................................................ 12
3.6 Default Parameter Banks............................................................................ 12
3.6.1 Parameter Bank........................................................................... 13
3.7 Measurement of System Parameters ......................................................... 14
3.8 Fault Detection and Alarms ........................................................................ 15
3.8.1 Alarm LOG................................................................................... 15
3.8.2 Alarm Dry Contacts ..................................................................... 16
4. MONITORING THE SYSTEM .............................................................................. 17
4.1 How to Navigate the Controller Keypad...................................................... 17
5. CONTROLLING THE SYSTEM ........................................................................... 19
5.1 Monitor and Control Functions.................................................................... 21
5.2 Changing the Battery Charge Mode ........................................................... 24
5.3 Testing Power System Components........................................................... 26
5.3.1 Battery Test ................................................................................. 26
5.3.2 LCD Panel/Alarm Buzzer/LEDs................................................... 26
5.3.3 Relays.......................................................................................... 26
5.4 Recalibrating the Power System's Measurements ..................................... 27
POWER SYSTEM CONTROLLER MODEL Introduction iii

SC2012U UNIVERSAL
Table of Figures
Figure 1: Front Panel Keypad ..................................................................................... 3
Figure 2: Cross Cable ................................................................................................. 7
Figure 3: Default Dry Contacts-Alarms Connections ................................................ 16
Figure 4: Control Function Tree ................................................................................ 20
Figure 5: Measuring Calibration Values with a DMM ................................................ 27
List of Tables
TABLE 1: SYSTEM CONTROLS ...................................................................................... 21
TABLE 2: RECTIFIER CONTROLS .................................................................................. 21
TABLE 3: ALARM CONTROLS ........................................................................................ 21
TABLE 4: LOG CONTROLS ............................................................................................ 22
TABLE 5: ADVANCED CONTROLS.................................................................................. 22
TABLE 6: SETUP CONTROLS ........................................................................................ 23
iv Introduction POWER SYSTEM CONTROLLER

1. INTRODUCTION
The SC2012U controller enables the user to control and monitor all components of
the PS2012 power supply system. It is designed specifically for use with 48Vdc
systems. The ability to set various configurations allows the user to adjust the system
to suit specific needs. The clear, simple, user-friendly graphic user interface (GUI)
makes the controller easy to use, configure and calibrate.
1.1 SC2012U’s Main Features

SC2012U’s main features include:
• Control of power system components/parameters:

• DC output voltage control
• Control of the LVD with threshold disconnection setup
• Forces the LVD to open and sets it back to normal
• Controller reboot
• Easily restored factory defaults
• Easily saved and restored user defaults (in addition to factory defaults)
• Operation with battery set (affects the battery test procedure)
• Tests of power system components
• Battery test, both manual and periodic/automatic triggering, protected
by an adjustable top time
• LCD Display-LED-buzzer test
• Relay test
• Alarms
• Six output dry contacts for alarm indication, which are entirely
configured by the user
• Alarm buzzer-mute controlled locally by a control button or remotely
by an application
• Setting the threshold levels for triggering alarms
• Phone number for modem dialing set by the user
• Event LOG – 255 cyclic event LOG (+ CLEAR)
• Embedded real-time clock backup for two weeks of voltage supply
absence.
• Remote monitoring and control
• User ID – an additional six-byte of nonvolatile identification
• User-friendly user interface
• LCD panel for displaying measurements and parameter values
• LED indicators displaying system status
• User adjustable parameters:
POWER SYSTEM CONTROLLER MODEL Introduction 1

SC2012U UNIVERSAL
• Battery test supply voltage and failure threshold levels adjustable by

the user
• AC voltage failure threshold (high and low) levels adjustable by the
user
• Separate DC voltage failure threshold (high and low) levels for
equalizing and floating charge modes adjustable by the user
• Battery over-temperature threshold level adjustable by the user
• Auto battery test period and top time adjustable by the user
• Auto equalizing period and top time adjustable by the user
• Independent voltage setup for both floating and equalizing modes
• A unique ID, which is determined by the manufacturer and by the user
• Calibration of ACV DCV LOAD-current and BATT current
measurements are easily performed by the user, thus reducing the
number of drift- and error effect without the need for vendor service.
• One-step current measurement offset (caused by hardware) strip off
• Optional features that the user can enable/disable
• Enable / Disable automatic equalizing
• Periodic/Auto and Manual boost mode, protected by an adjustable top
time
• Battery temperature coefficient and temperature compensation Enable
/ Disable determination adjustable by the user
• Battery current limit value and Enable / Disable determination
adjustable by the user
2 Introduction POWER SYSTEM CONTROLLER

2. SYSTEM CONTROLLER
The SC2012U system controller is housed in the power system’s rack alongside up to
24 rectifiers, that it monitors and controls as well as other components in the system
(i.e. LVDs, batteries, etc.).
The controller is a “Hot Swap” Plug-In model that can be replaced or switched on and
off during system operation without damaging or affecting either the controller or the
system's operation mode or components.
2.1 Front Panel
Figure 1: Front Panel Keypad
The SC2012U front panel contains the following:
1. LCD panel
2. Six LED status indicators
3. Six navigation keys for managing the controller
4. An audible alarm buzzer that warns of a fault or faults in the system
5. An DB9 RS232 socket that allows remote communication with the controller
2.1.1 LCD Panel Display

The LCD panel digitally displays the real-time status of a system parameter. The user
can change the nominal values of the parameter displayed on the LCD panel with the
Up and Down arrow buttons (see Figure 1 above).
2.1.2 LED Status Indicators

The color-coded LED lights indicate the real-time status of system components, as
described in the following table:
LED COLOR MEANING

AC Green A steady light indicates normal input voltage from the mains
AC Unlit Voltage from the AC input absent or out of range
DC Green A steady light indicates normal DC voltage
DC Unlit Indicates a fault in the DC voltage
POWER SYSTEM CONTROLLER MODEL System Controller 3

SC2012U UNIVERSAL
LED COLOR MEANING

DC Blink Indicates equalizing mode
RECT Red A steady light indicates a faulty rectifier
LVD Red A steady light indicates that the LVD is open (either the controller
system opened the LVD to prevent battery damage or the user
manually opened the LVD)
LVD Unlit An unlit LED indicates a normal operation mode.
BATT Green A steady light indicates that the last battery test passed
A flashing light indicates a battery test in progress
BATT Unlit An unlit LED indicates the last battery test failed.
ALARM Red A flashing light indicates that there is an unconfirmed
fault in the system.
A steady light indicates that the fault in the system has
been confirmed by the operator.
ALARM Unlit An unlit LED indicates that there are no active faults in the system.
4 System Controller POWER SYSTEM CONTROLLER

2.1.3 Navigation Keys

The following table describes the results of pressing each of the navigation keys:
BUTTON DESCRIPTION
ARROW KEYS Navigate between displays, lines on a display or data on a line
and modify.
ENTER Saves information or authorizes the controller to process the
commands
ESC Exits Setup or Editing mode and returns to the main display
without saving changes.
Pressing this key on the default display, confirms the alarm,
silences the buzzer, stops the ALARM LED from flashing,
performs LED and buzzer tests.
2.1.4 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 until the fault is no longer active, even if the
alarm buzzer has stopped.
When a fault occurs, the alarm emits intermittently until either the ESC button is
pressed or the fault is corrected. Note that the maximum audible alarm time may be
limited to 15 seconds..
2.1.5 DB9 Serial Port

This port enables remote communication via RS232 with the controller, allowing
remote monitoring and control of operation, status, and parameter setting.
2.2 RS232 Communication Protocol & Data

Structure
The SC2012U system controller supports a unique RS232 communication protocol.
This protocol allows a user at a remote location to send commands to the controller
and retrieve data and status information from it:
• The command packet (sent to the controller) includes the operation codes to
be carried out by the controller plus any data required for that operation.
• The retrieved packet (sent by the controller) includes all possible data that can
be supplied by the controller. It is sent every time a valid command packet is
received, even if the command packet only contains a non-operation
command.
2.2.1 General Information

The communication protocol adheres to the following general rules:

SC2012U UNIVERSAL
• The host PC and the controller communicate via Half-Duplex RS232 9600.N.1
RX, TX, GND lines with no flow control (neither hardware nor software).
• The host is always the master and the controller is the slave.
• The data is binary with no dedicated control characters.
• Data transmitted by each end has a constant length.
• Three elements are utilized for data reliability:
• three byte – header
• one byte - check sum
• three byte - termination
• On receiving a valid packet, the controller starts responding within 50 msec.
• On receiving a header start (0 × AC) a 500msec, a long reception window is
initiated. If a valid packet is received it is processed, otherwise, the controller
backs-off by initialising the reception counter.
2.2.2 Master
The master sends its packet, which includes the header, op-code, data, checksum and
termination. The ten-byte op-code bit-combination enables the user to perform one or
more functions simultaneously.
The 97-byte data should include operation-relevant data set by the user as op-code.
6 System Controller POWER SYSTEM CONTROLLER

2.2.3 Slave
The slave responds as soon as it receives a valid packet, which includes a header,
received_op-code, received_checksum, id, data, checksum and termination.
• The received_opcode is the last op-code received from the master.

• The received_checksum is the last checksum received from the master.
• The four-byte id consists of preprogrammed three bytes and an additional
byte, which may be programmed by the master.
• The 118-byte data always includes all the data or status information that the
user may request, i.e., every transaction relayed from the master to the slave
results in the retrieval of all possible data that the slave is able to supply.
Note: The data retrieved in a transaction does not include the changes made by the
host’s command (if any). Another retrieval should take place in order to receive the
values effected in the previous command.
Figure 2: SC2012U Cross Cable

SC2012U UNIVERSAL
3. THEORY OF OPERATION
SC2012U monitors and controls the PS2012 power supply system with:
• Nominal values of system parameters that can be setup by the user or imported
from a parameters bank
• Measurements of the system's input AC voltage and output DC voltage and
current.
• Responses to data received from the system
• Fault detection and alarms
3.1 PD Bus Communication

The controller uses the PD Bus (peripheral device bus) to communicate with the
rectifiers and converters. At regular preset intervals a message is sent to a rectifier or
converter (each of which have their own, individual addresses that were set during the
hardware definition process). Each rectifier and converter “listens” simultaneously to
the controller’s transmissions. The device with the transmitted ID address responds to
the ID address of the controller - which was also part of the message. In addition to
the address, the message also contains data for controller commands such as the
output voltage of the power supply or converter, the current limit, and the activation
and deactivation of the output stage.
The message transmitted back to the controller from the devices includes the device's:
address, voltage level it supplies, output current level, internal temperature, and which
the status (OK/Not OK) of its internal components.
3.2 Charge Modes

The system can run in either floating or equalizing battery charge mode. The system
normally operates in the floating mode, but it switches over to equalizing mode when
the batteries require additional or rapid charging. The voltage levels of both floating
and equalizing mode are user-defined.
8 Theory of Operation POWER SYSTEM CONTROLLER

3.2.1 Floating Mode

Floating mode normally supplies the batteries with current that charges them
continuously. The batteries are charged in this manner throughout most of the
system’s life. Battery charging switches to equalizing mode whenever there is a large
discharge (due to a voltage drop in the mains and the need for continuous current by
the load).
3.2.2 Equalizing Mode

You can determine when and if the system enters into equalizing mode. This
information is stored in the non-volatile memory.
There are two ways to initiate equalizing mode:
• Manually: You initiate it and set the charge time (the length of time
equalizing lasts), which can be anything from 4 to 72 hours. The system
automatically reverts back to floating mode when the charge time ends.
• Periodically: Periodic or automatic charging takes place every user-defined
number of months or after a power failure that lasts more than half an hour.
During periodic or automatic charging, the system behaves according to the
algorithm descried below. The system also exits this mode according to the
algorithm unless the algorithm justifies continuing on in equalizing mode. In
any case, equalizing does not last longer than a maximum length of time (Top
Time) that can be set by you.
3.2.3 Battery Charging Current Limit

The battery charging current can be limited by setting the maximum value the current
can reach. This is a user-defined value, as is the enabling/disabling of the current
limit. A current limit is set to prevent damage to the batteries which can occur if
batteries are fed a high current over a long period of time. The controller routinely
monitors the rectifiers’ output, checking that the output remains within the set battery
current limit without impeding the current supplied to the load.
3.3 Battery Test

The battery test checks if the batteries are functioning or faulty. The test can be
performed either manually (initiated by you) or automatically.
During the battery test the load remains connected to the system. The output voltage
from the rectifiers is decreased, so that the batteries supply the load current. This
discharges the batteries. The voltage of the rectifiers is brought to a value that allows
it to serve as a safety net in case that the batteries cannot supply the required current.
The controller calculates the time required for the test according to the discharge
current at the time, and the capacity of the batteries. If the battery voltage drops below
a preset threshold voltage during the battery test, the battery fails the test and is
considered faulty. If not, the battery is considered to be in working order.
The maximum time allowed for both the manual and the automatic battery test is set
by you. The test aborts once the preset time limit is reached.
POWER SYSTEM CONTROLLER MODEL Theory of Operation 9

SC2012U UNIVERSAL
3.4 Rectifiers and Converters Current Sharing

In systems with multiple rectifiers and/or converters, there is a need to coordinate
among all the rectifiers/converters an equal sharing of the total current consumption
(total of load currents and charges of batteries). Otherwise, there is a problem with the
supply of normal current and the situation occurs in which specific rectifiers supply
high current, over heat, and wear out because the other rectifiers don't contribute their
share - or contribute only part of it.
This problem is solved by the Current Sharing mechanism in which the controller
collects output current data from each rectifier, calculates the general average and
transmits the figure to all the rectifiers. The rectifiers check the current they provide,
change their charge current so that it corrects the current at the output according to the
average current transmitted by the controller to each rectifier. Correction of the
voltage is performed very gently and relatively slowly.
3.5 Setting Nominal Values

The values that control the following parameters of the power system can be set by
the user or imported from a parameter bank (see Default Parameter Banks, page 12):
• Output Voltage
• Battery Test
• Battery Charge Current
• Battery Temperature Compensation
• LVD Opening
• Alarm Thresholds
3.5.1 Output Voltage

The system output voltage set by the controller is affected by:
• Activated charge mode (floating/equalizing)

• Battery temperature compensation (if enabled)
• Battery test (if activated)
• Battery charge current limit (if enabled)
• Deviation of output voltage.
In the absence of a controller the output voltage reverts to the system's default output
voltage.

3.5.2 Battery Test

The user may manually initiate a battery test at any time via the panel menu or a
remote application. In addition, an enabled automatic battery test occurs whenever a
period of days (set by the user) has passed.
The battery test uses an algorithm involving the actual battery current and battery
capacity that is set by the user and which can always be modified by the user.
The formula for calculating the remaining battery time (in seconds) is:
[BATTERY CAPACITY (AH) × 180 / BATTERY CURRENT (A)] – ELAPSED TIME (sec)
In any event, the test time does not exceed the time limit parameter. Throughout the
test, the supply voltage is lowered to a defined voltage set by the user which allows
the battery to discharge. The controller continually checks the battery’s voltage,
waiting for it to cross the threshold set by the user as the criteria that indicates a bad
battery. If threshold is crossed, the test of the battery is aborted and the battery is
considered faulty. The results are stored separately in a non-volatile memory.
3.5.3 Battery Charge Temperature Compensation

The battery temperature is measured by two sensors. These real-time sensors are used
for determining the amount of temperature compensation required as well as the
criteria for activating the over-temperature alarm.
The battery current compensation effects, if enabled, the output voltage according to
the following formula, where K is the compensation value determined by the user.
VP (T°C) = VP (25°C) – 24 × K (T°C - 25°C)
Where the VP is limited according to the following formula:

VP (25°C) – 1.5 < VP < VP (25°C) + 2

SC2012U UNIVERSAL
3.5.4 LVD
The first and most important task of the LVD is to disconnect the batteries in the
event that a deep discharge is endangering the life of the battery. The user determines
the criteria for opening the LVD. The user also defines the hysteresis (the gap
between the opening and closing voltage of an LVD).
For debugging or maintenance purposes it is possible to turn OFF or normalize the

LVD, regardless of the system status.
3.5.5 Alarm Thresholds

The range of permitted values for system parameters. If the value of a system
parameter is outside this range, an alarm is triggered.
3.6 Default Parameter Banks

There are two categories of stored default values for parameters, which can be
retrieved at any time to become the current values of parameters:
• Factory defaults determined by Gamatronic. The user may retrieve them but
cannot modify them.
• The user default bank in which the current parameters can be copied and later
retrieved as default parameters.
The two options allow the user the flexibility and confidence of restoring factory
defaults as well as the convenience of retrieving parameters already stored as good
functioning ones.

3.6.1 Parameter Bank
The controller always uses the non volatile ACTUAL PARAMETERS BANK as its
reference for settings, alarms, etc. (normal operation). This bank can be updated by
the user via both the controller's panel and a remote software application. In addtion,
an entire bank can be copied into it. For this purpose, the user can choose to copy
either Factory or User Defaults to the actual bank.
Factory Defaults are rigidly determined by the factory, while User Defaults can be
created and saved by the user from a setup existing in the controller at any time.

SC2012U UNIVERSAL
3.7 Measurement of System Parameters

The system parameters described in the following table are constantly being measured
to provide updated data about their real-time status. The permitted nominal value
range for these parameters is set by the user or the manufacturer. If the monitored
value for these parameters is out of the permitted range, an alarm is triggered. (See
Fault Detection and Alarms, page 15 for a table listing the faults linked to each alarm
message.
PARAMETER STATUS INFORMATION

AC Input Line AC voltage from the mains
DC Output Line DC output voltage for equalizing and floating modes
Batt Line Battery voltage
Load Current Current drawn by the load calculated by subtracting the load current
from the rectifier current
Rectifier Current Sum of the total output current from all the rectifiers
Battery Current Current to/from the battery that activates the current limit feature
(if enabled)
Battery Temperature Temperature of batteries
Dry In Contacts Circuit breakers open or closed
Note: The alarm levels for DC Output are set separately for floating and equalizing
modes so that there are suitable alarm levels for whichever mode is running at any
given time.

3.8 Fault Detection and Alarms

The controller generates alarms in response to the power system faults described in
the following table. When an alarm becomes active the Fault LED lights up, the
alarm buzzer sounds, and an alarm message - marked by a Time Stamp - is recorded
in the Event Log. One of the LED status indicators may be lit or unlit.
Each alarm remains active for as long as the fault remains active. It disappears as
soon as the fault no longer exists. The exception to this is a failed battery test.
Batteries must pass the battery test for their alarm status to revert to normal after a
controller reset or a battery failure.
The alarm message associated with each fault is itemized in Table 3.
3.8.1 Alarm LOG

Each event is recorded in an event LOG which contains the history of the last 255
power system faults along with information describing each event and when it
occurred.
When viewing the log, the LCD will display in Last In First Out (LIFO) mode so that
the most recent incident will appear first. Pressing the Enter button will also restart
the log view, starting from the last entry.
The display shows the date/time, error number and event type (in or out) plus a brief
description. The cd control buttons allow you to navigate and scroll through the past
error logs, and the ef buttons provide you with the DC voltage and status of each
alarm dry-contact connector at the time of the alarm trigger.
The log file can be cleared at any time, using the 8th function in Operations menu. See
Figure 4 on page 3.

SC2012U UNIVERSAL
3.8.2 Alarm Dry Contacts

Six dry contacts are used for direct alarm activation. Using the controller keypad or
by remote access, the user can connect a dry contact to any (or none) of the 32 listed
alarms. An alarm can be connected to more than one dry contact and a dry contact can
be connected to more than one alarm. When an alarm assigned to a dry contact is
activated, the dry contact is also activated.
Dry Outs
1 2 3 4 5 6 Dry Out Alarm
AC input voltage exceeds maximum settings
AC input voltage is lower than minimum
DC voltage exceptionally low – Equalizing or floating
DC voltage below minimum – Equalizing or floating
DC voltage exceeds maximum – Equalizing or floating
Battery circuit breaker is OPEN
Battery temperature exceeds maximum
Last battery test failed (non-volatile message)
Battery circuit breaker is OPEN
Dry In is OPEN
Communication with rectifier(s) – No response
Forced OPEN
-UNUSED-
One or more load circuit breakers are open
-UNUSED-
AC input surge has blown
Battery test time-stamp
Equalizer test time-stamp
DC voltage exc. high – switches OFF 1 by 1 until DC within range
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
-UNUSED-
Controller time-stamp
-UNUSED-
Figure 3: Default Dry Contacts-Alarms Connections

4. MONITORING THE SYSTEM

The user can monitor and manage the power system either remotely or by using the
controller keypad.
4.1 How to Navigate the Controller Keypad

To control the PS2012 you will need to use the navigation buttons on the SC2012U
using the tree illustrated in Figure 4: Control Function Tree. To start, press the Enter
button. Using the up/down arrows will allow you to navigate the tree. For example,
press the down arrow and the LCD panel will display 01 SYSTEM. Press it again and
the LCD will display 02 RECTIFIERS, press the down arrow once again and the
LCD will display 03 ALARMS. This time press Enter to confirm that this is the menu
branch you need and want to start. The LCD panel will now display 01 AC HI.
If you get lost or simply wish to finish, simply press Esc to quit.
To monitor the system in Editing Mode:

1. Press Enter to start.
2. Use the arrow buttons to reach the field code for the parameter.
3. Press Enter to display the current value of that field code
4. Press Esc to exit Editing Mode.
As illustrated in Figure 4 on page 20, the control function tree has 5 main branches:
• System
• Rectifiers
• Alarms
• Log
• Advanced
To navigate at this level, use the and navigation keys on the keypad and press
Enter to make the selection.
Similarly, to navigate to lower levels, use the and navigation keys on the keypad
and press Enter to make the selection. To effect changes, use theandnavigation
keys on the keypad.
For example, to access the date setup, from the main screen (press ESC if necessary):
1. Press Enter (to proceed into the tree)
2. Press until the panel displays ADVANCED
3. Press Enter (to proceed into the ADVANCED branch)
4. Press until item 14 is displayed with DATE SETUP
5. Press and to set the date
POWER SYSTEM CONTROLLER MODEL Monitoring the System 17

SC2012U UNIVERSAL
6. Press Enter to set.
7. Press Esc to return to the main screen.
18 Monitoring the System POWER SYSTEM CONTROLLER

5. CONTROLLING THE SYSTEM

Using the navigation keys, the versatile SC2012U keypad gives you full control over
your power system as illustrated in Figure 4 on page 20.
POWER SYSTEM CONTROLLER MODEL Controlling the system 19

SC2012U UNIVERSAL
ENTER
SYSTEM RECTIFIERS ALARMS LOG ADVANCED

PASSWORD
<==EVENTS==>
AC HI 01 SETUP
01
(See SETUP tree)
AC RECT #1 AC LO 02
02 FLOATING VOLT
VOLTAGES RECEIVE
CONFIG 03 EQUAL VOLT
PROTOCOL
DC LOLO 03
TRANSMIT NO. OF 04 BAT TEST VOLT
PROTOCOL RECTS
SYS ALARM
DC LO 04 BATT TEST ALARM
CURRENT REC # BATTERY
05
RECT #2 CAPACITY
06 EQ LO ALARM-V
DC HI 05
RECEIVE
PROTOCOL HI/LO CAP. 07 EQ HI ALARM-V
LOAD BATT CB 06
TRANSMIT
CURRENT PROTOCOL ASSIGN DRY OUT 08 FL LO ALARM-V
TEMP HI 07
09 FL HI ALARM-V
RECT #3 DRY 1
BATT RECEIVE BAT TST 08 10 FL LLO ALARM-V
VOLT/CURR PROTOCOL DRY 6
11 EQ LLO ALARM-V
TRANSMIT LVD CB 09
PROTOCOL
CALIB 12 LVD VOLTAGE
TEMP USER 10 ACV PHASE 1 13 TIME SETUP

ACV PHASE 2
RCT COM 11 ACV PHASE 3 14 DATE SETUP
BATT CURR
BATT CURR OFFSET 15 SITE ID
RECTIFIER LVD OPEN 12 BATT VOLT
STATUS RECT #24 16
ENAB AUTO EQ
DC VOLT
13
17 ENAB TEMP COMP
ALARM EN/DIS
DRY-IN BROADCAST LOAD CB 14 18 TEMP COMP VALUE
STATUS RECEIVE
OPERATIONS 19 TEST TOP TIME
PROTOCOL
15 CHARGE MODE
TRANSMIT 20 TEST PERIOD
PROTOCOL BATTERY TEST
DRY-OUT SURGE 16 LVD ON/NORM EQ TOP TIME
STATUS 21
REBOOT
TESTTS 17 DRY OUT TEST
22 EQ PERIOD
SET RECTS ON EN CURR LIM

SC2012U Navigation Keys EQU_TS 18
23
SET RECT OFF
24 CURR LIM VALUE
19 DEFAULTS
25 ENABLE AUTO TEST
RESET FACTORY 26 LVD HYST VOLT

DEFAULTS
SAVE USER 27 SOFT-ID
STARTUP 31 DEFAULTS
28 AC LO ALARM-V
RESTORE FACTORY
32 DEFAULTS
29 AC HI ALARM-V
COMMS
30 OVER TEMP
PASSWORD 31 BACKLIGHT
32 BUZZER DUR
33 DC TOO HI
Figure 4: Control Function Tree
20 Controlling the system POWER SYSTEM CONTROLLER

5.1 Monitor and Control Functions

Table 1: SYSTEM MONITOR
LCD Display Description
AC VOLTAGES AC input voltages
SYS CURRENT Total output current
LOAD CURRENT Current drawn by load
BATT VOLT/CURR Battery voltage/current readings
TEMP Battery temperature
RECTIFIER STATUS z = Working and responding, { = Not working/responding
DRY-IN STATUS 5 – { = Open or z = closed
DRY-OUT STATUS 6 – { = Open or z = closed
Table 2: RECTIFIER MONITOR

RECT # RECEIVE Voltage, current and temperature.
PROTOCOL If there is no response, the display will show all ‘-‘
RECT # TRANSMIT Control codes
PROTOCOL
BROADCAST RECEIVE Broadcast to all
PROTOCOL
BROADCAST TRANSMIT Broadcast to all
PROTOCOL
Table 3: ALARM MONITOR

# LCD Display Description
1 AC_HI AC input voltage exceeds maximum settings
2 AC_LO AC input voltage is lower than minimum
3 DCLOLO DC voltage exceptionally low – Equalizing or floating
4 DC_LO DC voltage below minimum – Equalizing or floating
5 DC_HI DC voltage exceeds maximum – Equalizing or floating
6 BATTCB Battery circuit breaker is OPEN
7 TEMP HI Battery temperature exceeds maximum
8 BATTST Last battery test failed (non-volatile message)
9 LVD_CB Battery circuit breaker is OPEN
10 USER_ Dry In is OPEN
11 RCTCOM Communication with rectifier(s) – No response
12 LVDOPN Forced OPEN
13 ------ -UNUSED-
14 LOADCB One or more load circuit breakers are open
15 ------ -UNUSED-

SC2012U UNIVERSAL

16 SURGE AC input surge has blown
17 TESTTS Battery test time-stamp
18 EQU_TS Equalizer test time-stamp
19 DCTOHI DC voltage exceptionally high – switches OFF 1 by 1 until DC is
within range
20 ------ -UNUSED-
21 ------ -UNUSED-
22 ------ -UNUSED-
23 ------ -UNUSED-
24 ------ -UNUSED-
25 ------ -UNUSED-
26 ------ -UNUSED-
27 ------ -UNUSED-
28 ------ -UNUSED-
29 ------ -UNUSED-
30 ------ -UNUSED-
31 STARTUP Controller time-stamp
32 ------ -UNUSED-
Table 4: LOG MONITOR

ALARM REC # 0 … 255 Time/date, voltage, event type, dry-in status of alarm trriggers
Table 5: ADVANCED CONTROLS & SETTINGS

1 SETUP (See Table 6)
2 CONFIG: NO. OF
RECTS
3 CONFIG: BATTERY All
CAPACITY
4 CONFIG: HI/LO CAP
5 ASSIGN DRY OUT #
6 CALIB: ACV PHASE 1 Using a VOM
9 CALIB: BATT CURR Using a VOM
10 CALIB: BATT VOLT Using a VOM
11 CALIB: DC VOLT Using a VOM


12 ALARM EN/DIS
13 OPERATIONS: Floating or equalizing charge
CHARGE MODE
14 OPERATIONS: BATT Start, stop, clear failed
TEST
15 OPERATIONS: LVD
OFF/NORM
16 OPERATIONS: Controller will reboot automatically.
REBOOT
17 OPERATIONS:DRY Check each one
OUT TEST
18 OPERATIONS: SET Turns all rectifiers ON
RECTS ON
19 OPERATIONS: SET Turns specific rectifier OFF
RECT OFF
20 DEFAULTS: STORE Store factory defaults – cannot be changed
FACTORY DEFAULTS
21 DEFAULTS: SAVE Store user defined defaults
FACTORY DEFAULTS
22 DEFAULTS: RESTORE Restore user defined defaults
FACTORY DEFAULTS
23 DEFAULTS: COMMS
24 PASSWORD CHANGE/MODIFY PASSWORD
Table 6: SETUP CONTROLS

1 ------ -UNUSED-
2 FLOATING VOLT Output floating charge setup
3 EQUAL VOLT Output equalizing charge setup
4 BATT TEST VOLT Reduce rectifier voltage during battery test
5 BATT TEST ALARM Last battery test failed
6 EQ LO ALARM-V Threshold voltage low (equalizing)
7 EQ HI ALARM-V Threshold voltage high (equalizing)
8 FL LO ALARM-V Threshold voltage low (floating)
9 FL HI ALARM-V Threshold voltage high (floating)
10 FL LLO ALARM-V Threshold voltage exceptionally low or absent (floating)
11 EQ LLO ALARM-V Threshold voltage exceptionally low or absent (equalizing)
12 LVD VOLTAGE Cutout if voltage from all batteries below minimum
13 TIME SETUP Time setup for LCD display
14 DATE SETUP Date setup for LCD display

SC2012U UNIVERSAL

15 SITE ID Unique site identifier number
16 ENAB AUTO EQ Automatic equalizer - feature enable/disable
17 ENAB TEMP COMP Battery temperature compensation - feature enable/disable
18 TEMP COMP VALUE Coefficient (relative to 25°C)
19 TEST TOP TIME Limit test time (minutes)
20 TEST PERIOD How often to test (days)
21 EQ TOP TIME Limit equalizertime (hours)
22 EQ PERIOD How often to charge equalizing (days)
23 EN CURR LIM Current limiter enable/disable
24 CURR LIM VALUE Current limiter (amps)
25 ENABLE AUTO TEST Automatic battery test enable/disable
26 LVD HYST VOLT LVD hysteresis voltage
27 SOFT-ID 0-255 for protocol use
28 AC LO ALARM-V AC input voltage low
29 AC HI ALARM-V AC input voltage high
30 OVER TEMP Battery temperature
31 BACKLIGHT Stays on for 4 minutes
32 BUZZER DUR Buzzer duration – 15 seconds or non-stop
33 DC TOO HI DC voltage to high
5.2 Changing the Battery Charge Mode

There are two battery charge modes, each of which has different settings and output
voltages:
• Floating - Normal battery charging mode

• Equalizing - Forced, accelerated battery charging mode
If the automatic equalizing mode is enabled, the system automatically goes into
equalizing mode after:
• the passage of a set period of time

• a power failure or controller startup (after a delay of ten minutes)
The equalizing session is terminated when either a pre-set time limit is reached or the
charge current becomes low (1/10 of the battery’s capacity in amperes).
Note: In the event of a power failure an equalizing mode session is aborted.

The user can manually switch to either of these modes at any time.
To manually switch to Equalizing mode: Select item 16 from the ADVANCED

menu and using the left right arrows, select ENABLE.

To manually switch to Floating mode: Select item 16 from the ADVANCED menu
and using the left right arrows, select DISABLE.

SC2012U UNIVERSAL
5.3 Testing Power System Components

The user can test three power system components to verify they are working properly:
• Batteries
• LCD panel/Alarm buzzer/LEDs
• Relays
5.3.1 Battery Test

The system automatically tests the battery periodically. The user can set the length of
time between battery tests. If the battery tests exceeds the time specified, it is
automatically aborted.
There are 2 possible methods of testing the batteries:
While connected to the rectifier the voltage should reduce to 45V (or as defined
by the user). If while testing the voltage drops below 46V(or as defined by the
user), the battery is faulty.
At controller setup, the battery capacity should total the battery capacity string.
To manually start a battery test: Select item 4 from the SYSTEM menu and using
the left right arrows, select ENABLE.
To manually abort an ongoing battery test: Select item 4 from the SYSTEM menu
and using the left right arrows, select DISABLE.
5.3.2 LCD Panel/Alarm Buzzer/LEDs

Devices in the controller are automatically tested to check if they are all working
properly whenever the controller is turned on.
5.3.3 Relays
There are six dry out relays. A technician may test any of them in editing mode at any
time to check if it is working.
To perform this test: Select item 3 from the ADVANCED menu.

Note: Only one relay is disabled at a time. Disabling a second relay automatically
enables the first one. Pressing ESC to exit Editing Mode automatically enables all
disabled relays.

5.4 Recalibrating the Power System's

Measurements
The power system is calibrated before it leaves the factory to guarantee precise
voltage and current measurements by removing measurement inaccuracies on the
hardware path. However, if it becomes necessary to recalibrate it again, an authorized
technician can easily recalibrate the system's measured voltages and currents at any
time remotely via software or directly via the controller.
Before the system can be recalibrated the real value of the measurements must be
determined with an accurate, 3-digit Digital Multi Meter (DMM). These values are
then used to recalibrate the system (see Figure 5 below).
To determine the real value of system measurements:

1. Disconnect the system's batteries (so that Load Current = Rectifier Current).
2. Use a DMM to measure the real value of the measurements as described in
Figure 5 and the table below.
Figure 5: Measuring Calibration Values with a DMM

To calibrate voltages:
3. Select item 4 from the ADVANCED menu
4. Press Enter to start the calibration
5. Press either or navigation keys on the keypad, select the next voltage to
be set and press Enter.
6. Using the keypad, enter the readings you obtained from your DMM, and press
enter.
To calibrate the battery current offset:

Before attempting to calibrate the battery current, clear the offset as follows:
7. Isolate both the battery and the load.

8. From the CALIBRATE menu, press either or navigation keys on the
keypad and press Enter to select BATT CLEAR OFFSET and press Enter.
To calibrate the battery current:

SC2012U UNIVERSAL
1. Connect the (fully charged) batteries.

2. With the AC input disconnected, connect a heavy load.
3. Connect your DMM over the shunt and from the mV reading calculate the
current.
4. Enter the current reading using the navigation keys and press Enter to save
the setting.
Note: To obtain the most accurate current reading, use a load rated as close a
possible to a live load.
MEASUREMENT WHAT TO SET THE WHERE TO CONNECT
DMM TO MEASURE THE DMM WHEN
ACV PHASE 1 AC Volts AC input (Vac) Phase 1
BATT CURR Ampere Shunt (mV) Near full load
BATT CURR OFFSET - - Battery removal
BATTERY VOLT DC Volts Battery Terminals
DC VOLT DC Volts DC Output


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Gamatronic Electronic Industries Ltd.

POWER SYSTEM CONTROLLER

User Guide and Instruction Manual

Har Hotzvim Industrial Park,

Gamatronic Electronic Industries Ltd.

ii User Guide and Instruction Manual Gamatronic Electronic Industries Ltd.

POWER SYSTEM CONTROLLER MODEL Introduction iii

iv Introduction POWER SYSTEM CONTROLLER

1.1 SC2012U’s Main Features

• Control of power system components/parameters:

POWER SYSTEM CONTROLLER MODEL Introduction 1

• Battery test supply voltage and failure threshold levels adjustable by

2 Introduction POWER SYSTEM CONTROLLER

2.1 Front Panel

Figure 1: Front Panel Keypad

The SC2012U front panel contains the following:

2.1.1 LCD Panel Display

2.1.2 LED Status Indicators

LED COLOR MEANING

POWER SYSTEM CONTROLLER MODEL System Controller 3

LED COLOR MEANING

4 System Controller POWER SYSTEM CONTROLLER

2.1.3 Navigation Keys

2.1.4 Audible alarm buzzer

2.1.5 DB9 Serial Port

2.2 RS232 Communication Protocol & Data

2.2.1 General Information

POWER SYSTEM CONTROLLER MODEL System Controller 5

6 System Controller POWER SYSTEM CONTROLLER

• The received_opcode is the last op-code received from the master.

Figure 2: SC2012U Cross Cable

POWER SYSTEM CONTROLLER MODEL System Controller 7

3.1 PD Bus Communication

3.2 Charge Modes

8 Theory of Operation POWER SYSTEM CONTROLLER

3.2.1 Floating Mode

3.2.2 Equalizing Mode

There are two ways to initiate equalizing mode:

3.2.3 Battery Charging Current Limit

3.3 Battery Test

POWER SYSTEM CONTROLLER MODEL Theory of Operation 9

3.4 Rectifiers and Converters Current Sharing

3.5 Setting Nominal Values

3.5.1 Output Voltage

• Activated charge mode (floating/equalizing)

10 Theory of Operation POWER SYSTEM CONTROLLER

3.5.2 Battery Test

3.5.3 Battery Charge Temperature Compensation

VP (T°C) = VP (25°C) – 24 × K (T°C - 25°C)

Where the VP is limited according to the following formula:

POWER SYSTEM CONTROLLER MODEL Theory of Operation 11

For debugging or maintenance purposes it is possible to turn OFF or normalize the

3.5.5 Alarm Thresholds

3.6 Default Parameter Banks

12 Theory of Operation POWER SYSTEM CONTROLLER

3.6.1 Parameter Bank

POWER SYSTEM CONTROLLER MODEL Theory of Operation 13

3.7 Measurement of System Parameters

PARAMETER STATUS INFORMATION

14 Theory of Operation POWER SYSTEM CONTROLLER

3.8 Fault Detection and Alarms

3.8.1 Alarm LOG

POWER SYSTEM CONTROLLER MODEL Theory of Operation 15

2. Press until the panel displays ADVANCED

4. Press until item 14 is displayed with DATE SETUP

5. Press and to set the date