Gamatronic POWER PLUS Technical Manual

P

P

O

WEERR

O

W

+

+

MMoodduullaarr UUPPSS ssyysstteemm

1100 kkVVAA ttoo 110000 kkVVAA,, 33xx440000 VV

TTeecchhnniiccaall GGuuiiddee

Release 2.1, September 2009

Har Hotzvim Industrial Park,

14 Hartom St., PO Box 45029, Jerusalem 91450, Israel

Tel: [phone] Fax: [phone]

Email: [e-mail] Website: www.gamatronic.com

Gamatronic Electronic Industries Ltd.

Har Hotzvim Industrial Park
14 Hartom St., PO Box 45029, Jerusalem 91450 Israel
Tel: [phone] Fax: [phone]
Email:

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 2009 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, reproduced or disclosed to third parties,
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 affected 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, 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.

[e-mail] Website: www.gamatronic.com

ii

Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

TABLE OF CONTENTS

1. SYSTEM STRUCTURE........................................................................................................ 1

2. FUNCTIONAL OVERVIEW.................................................................................................. 4

2.1 UPS Basic Module (10kVA / 8KW).......................................................................... 4

2.1.1 Single UPS Module Specifications ....................................................... 9

2.2 UPS System Controller ......................................................................................... 10

2.2.1 System Controller Specifications.......................................................12

2.3 Static Switch (ST/SW) Module.............................................................................. 12

3. SYSTEM INTERCONNECTION......................................................................................... 15

3.1 internal System wiring .......................................................................................... 16

3.1.1 The Power+ always requires a neutral line........................................ 20

3.1.2 UPS Module – Connectors Description.............................................. 24

3.1.3 UPS Module Pin Assignment Table.................................................... 25

3.2 DC Distribution Panel Cabling ............................................................................. 26

3.2.1 DC Fuses ............................................................................................... 28

3.3 AC Input Fuses ...................................................................................................... 29

3.4 AC Distribution Compartment..............................................................................30

3.5 AC Input/Output Main Terminals.......................................................................... 31

3.6 Static Switch Connections ................................................................................... 32

3.7 System Controller Connections........................................................................... 33

3.7.1 PC714 – the controller card.................................................................33

3.8 Setting the Shelf Address..................................................................................... 36

3.9 F.A.Q. (Frequently Asked Questions).................................................................. 39

3.9.1 Batteries ................................................................................................ 39

3.9.2 General................................................................................................... 40

3.9.3 Menus..................................................................................................... 41

3.9.4 Installation............................................................................................. 42

3.9.5 Mechanics ............................................................................................. 43

3.9.6 Common problems............................................................................... 43

4. SYSTEM INSTALLATION ................................................................................................. 45

4.1 Inspections to be Performed Prior to Installation.............................................. 47

4.2 Installation Procedure and System Start-up....................................................... 48

4.3 Initial Start-up Sequence ...................................................................................... 49

4.4 Checks to be Performed Following Initial Startup.............................................51

4.5 Special considerations for 1-phase output......................................................... 52

4.5.1 Dip-switch settings on the modules................................................... 52

4.5.2 Wiring of input and output terminals.................................................. 52

4.5.3 System start-up..................................................................................... 53

4.6 DIP switch settings of the UPS modules ............................................................ 54

5. USING THE SYSTEM CONTROLLER.............................................................................. 55

5.1 System information display.................................................................................. 56

5.2 Display UPS module data ..................................................................................... 59

5.3 Setting the Number of UPS Modules................................................................... 61

5.4 Retrieving History (LOG of Events).....................................................................62

5.5 System Controller Alarms.....................................................................................65

6. BATTERIES .......................................................................................................................66

6.1 Batteries and Configurations...............................................................................66

6.1.1 Internal Batteries .................................................................................. 66

6.1.2 External Batteries.................................................................................67

6.2 Installing and connecting the Batteries .............................................................. 67

Power+ Technical Guide

iii

Gamatronic Electronic Industries Ltd.

6.2.1 Configuring the batteries to the system............................................. 69

7. DRY CONTACTS AND ALARM TERMINALS..................................................................70

7.1 DC Current measurement..................................................................................... 71

7.2 Temperature sensor..............................................................................................71

7.3 User-defined alarms..............................................................................................71

8. PERIODIC MAINTENANCE .............................................................................................. 72

8.1 Objectives of the Periodic Maintenance ............................................................. 72

8.2 Recommended Tools ............................................................................................ 72

8.3 Maintenance Procedures and Report.................................................................. 73

9. TROUBLESHOOTING....................................................................................................... 76

10. SYSTEM CONTROLLER & COMMUNICATIONS............................................................ 80

10.1 Introduction............................................................................................................ 80

10.2 SCC POWER+ characteristics.............................................................................. 80

10.3 Controller User Interface ...................................................................................... 81

10.4 Service Utilities...................................................................................................... 81

10.4.1 Start-up Screens................................................................................... 81

10.4.2 The Main Menu...................................................................................... 84

11. SETUP PROCEDURES.....................................................................................................85

11.1 Setting Alarm Thresholds..................................................................................... 85

11.1.1 Setting Alarm Vibration Parameters................................................... 86

11.1.2 Setting the Integration Factor for Alarms .......................................... 86

11.1.3 'Auto' Test Batteries............................................................................. 86

11.2 Setting Password Level 1 ..................................................................................... 86

11.3 Adding a POWER module..................................................................................... 87

11.4 System Controller setup verification................................................................... 88

11.4.1 ACCESS................................................................................................. 88

11.4.2 SCREEN 1.............................................................................................. 88

11.4.3 SCREEN 2.............................................................................................. 89

11.4.4 SCREEN 3.............................................................................................. 89

12. REPLACEMENT PROCEDURES...................................................................................... 90

12.1 UPS module............................................................................................................ 90

12.2 System Controller module.................................................................................... 91

12.3 Static Switch module ............................................................................................ 92

12.4 Replacing the controller's flash memory............................................................ 93

13. USING SERVICE PROGRAMS......................................................................................... 95

13.1 Access to Service Mode ....................................................................................... 95

13.2 Selecting the Controller’s Low Level Utilities .................................................... 96

13.3 Setting the Network Addresses ........................................................................... 96

13.3.1 Setting the SNMP Factor...................................................................... 96

13.4 Configuring Dry Contacts and Alarms................................................................97

13.4.1 Linking Alarms to Dry Contacts.......................................................... 97

13.4.2 Enabling and disabling specific alarms.............................................97

13.5 Calibrating Measurements.................................................................................... 98

13.6 Controller Self-Test ............................................................................................... 98

13.7 Battery Test............................................................................................................ 98

13.7.1 Periodic/Automatic Battery Test......................................................... 98

14. MONITORING THE SYSTEM............................................................................................ 99

14.1 Power Meter ........................................................................................................... 99

14.2 System Operating Times..................................................................................... 100

iv

Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

14.3 Main DIP Switch Status....................................................................................... 100

14.4 Panel and Slave DIP Switch Status ................................................................... 101

14.5 SC POWER+ Internal Power Supply..................................................................101

14.6 System Temperature...........................................................................................101

14.7 Internal Communication ..................................................................................... 102

14.8 Monitoring System Components.......................................................................103

14.8.1 Monitoring the Batteries .................................................................... 103

14.8.2 Monitoring Alarms.............................................................................. 104

14.9 After Using the Emergency Power Off .............................................................. 104

15. SYSTEM SPECIFICATIONS ........................................................................................... 105

16. SYSTEM MODULES ORDERING INFORMATION......................................................... 106

LIST OF FIGURES

Figure 1-1: Block diagram ...................................................................................................... 1

Figure 1-2: Sub-assemblies.................................................................................................... 2

Figure 1-3: 10kVA configuration............................................................................................2

Figure 1-4: 50kVA configuration............................................................................................3

Figure 1-5: 100kVA configuration..........................................................................................3

Figure 2-1: Single UPS Module- Front/Rear View ................................................................ 4

Figure 2-2: Block diagram of a single UPS Module ............................................................. 5

Figure 2-3: Power section of the PFC in a single UPS module .......................................... 6

Figure 2-4: Input currents of the PFC (without filters) ........................................................ 6

Figure 2-5: PFC control scheme ............................................................................................ 7

Figure 2-6: DC/AC inverter principal topology.....................................................................8

Figure 2-7: System controller - Front panel........................................................................ 10

Figure 2-8: System controller - Block diagram................................................................... 11

Figure 2-9: ST/SW front panel view ..................................................................................... 13

Figure 2-10: ST/SW block diagram ...................................................................................... 13

Figure 2-11: 3-Phase ST/SW block diagram ....................................................................... 14

Figure 3-1: Power+ system - Modular structure................................................................. 15

Figure 3-2: Schematic of a 3:1 Phase 30kVA POWER+ System....................................... 16

Figure 3-3: Schematic of a 3-Phase 30kVA POWER+ System.......................................... 17

Figure 3-4: POWER+ System - Rear View...........................................................................18

Figure 3-5: Control PCB and flat cable................................................................................ 19

Figure 3-6: Wrong way to connect UPS with grounded-neutral-generator..................... 21

Figure 3-7: Acceptable connection for grounded generator and 4-pole switch............. 22

Figure 3-8: Preferred generator (neutralized) and connection (3-pole)........................... 23

Figure 3-9: UPS module – Rear view...................................................................................24

Figure 3-10: UPS module connectors - Pin assignments ................................................. 24

Figure 3-11: DC distribution panel (50KVA model)............................................................ 27

Figure 3-12: DC distribution. panel (100kVA model) ......................................................... 27

Figure 3-13: DC fuses on front side of DC dist. panel (50KVA model) ............................ 28

Figure 3-14: DC fuses on front of DC dist. panel (100KVA model) .................................. 28

Figure 3-15: UPS modules - AC input fuses (100KVA model) ........................................... 29

Figure 3-16: AC input fuse assignments (50KVA model).................................................. 29

Figure 3-17: AC distribution.................................................................................................30

Figure 3-18: AC distribution panel (100KVA model).......................................................... 30

Figure 3-19: AC distribution panel (50KVA model)............................................................ 30

Figure 3-20: Input & output main terminals........................................................................ 31

Figure 3-21: Static switch terminals – Rear view ............................................................... 32

Figure 3-22: System controller outside the shelf - Rear view...........................................33

Figure 3-23: Front side of PC714 card................................................................................. 34

Figure 3-24: Rear of PC714 – white rectangle indicates jumper area .............................. 34

Figure 3-25: The jumpers on PC714 .................................................................................... 34

Figure 3-26: The PC917 Control PCB on a shelf – general view....................................... 36

Power+ Technical Guide

v

Gamatronic Electronic Industries Ltd.

Figure 3-27: DIP switches on PC719 card– close-up......................................................... 37

Figure 3-28: Recommended master/slave DIP switch settings........................................37

Figure 3-29: DIP switch settings...........................................................................................38

Figure 4-1: POWER+ system connections.......................................................................... 45

Figure 4-2: Switch and wire ratings for 10-100kVA installation.......................................46

Figure 4-3: Start-up screen 1................................................................................................49

Figure 4-4: Start-up screen 2................................................................................................49

Figure 4-5: Start-up screen 3................................................................................................49

Figure 4-6: Start-up screen 4................................................................................................49

Figure 4-7: Normal display of the controller LCD (default)............................................... 50

Figure 4-8: Example of dip switch setting for 3/3 phase, 50 Hz UPS...............................53

Figure 5-1: The controller’s main menu.............................................................................. 55

Figure 5-2: Main menu option 1 ("System")........................................................................ 56

Figure 5-3: System DC voltages........................................................................................... 56

Figure 5-4: Output power factor 1........................................................................................ 57

Figure 5-5: Input power factor 1...........................................................................................57

Figure 5-6: Overall phase voltages/currents ...................................................................... 57

Figure 5-7. General timers and counters ............................................................................ 57

Figure 5-8. Jumper setting and general information ......................................................... 58

Figure 5-9. Internal controller voltages...............................................................................58

Figure 5-10: Main Menu option 2 (“UPS Module”) .............................................................. 59

Figure 5-11: LCD Panel – Selection ..................................................................................... 60

Figure 5-12: Module phase voltages/currents.................................................................... 60

Figure 5-13: Battery voltages, I-active current...................................................................60

Figure 5-14: Controller menu #2 .......................................................................................... 61

Figure 5-15: Controller menu #3 .......................................................................................... 61

Figure 5-16: Controller menu #4 .......................................................................................... 61

Figure 5-17: Number of UPS modules................................................................................. 61

Figure 5-18: Log display ....................................................................................................... 62

Figure 6-1: 40kVA N+1 System with Internal Batteries...................................................... 66

Figure 6-2: Internal Battery Drawer – Exploded View........................................................67

Figure 6-3: Connection diagram for external battery ........................................................ 68

Figure 7-1: Location of dry contacts at rear of POWER+ controller module..................70

Figure 7-2: Dry Contacts “group A” (as per Figure 7-1).................................................... 70

Figure 7-3: Dry Contacts “group B” (as per Figure 7-1).................................................... 71

Figure 9-1: UPS module front panel .................................................................................... 76

Figure 12-1: PC575 ................................................................................................................ 93

Figure 12-2: Extracting the EPROM..................................................................................... 93

Figure 13-1: Low level utility menu (SC2012 menu) .......................................................... 96

Figure 14-1: Key panel .......................................................................................................... 99

LIST OF TABLES

Table 2-1 Single UPS Module Specifications........................................................................ 9

Table 2-2: System controller specifications.......................................................................12

Table 3-1: UPS module pin assignment and function ....................................................... 25

Table 3-2: Jumpers on PC714 .............................................................................................. 35

Table 3-3: DIP switch setup in a 100kVA system (X = don't care).................................... 38

Table 4-1: Power Configuration DIP Switch Settings........................................................ 53

Table 5-1: Controller main menu options ............................................................................ 55

Table 5-2: Format of log messages ..................................................................................... 62

Table 5-3: Log Messages "description" field...................................................................... 63

Table 5-4: Static Switch transfer code (for LOADBP event) ............................................. 64

Table 5-5: System controller alarms..................................................................................... 65

Table 9-1: UPS Module Indicators........................................................................................ 77

Table 9-2: Troubleshooting table......................................................................................... 78

Table 10-1: General information screen.............................................................................. 83

vi

Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Table 10-2: Main Menu functions......................................................................................... 84

Table 11-1: Setup Menu options .......................................................................................... 85

Table 11-2: Setting alarm thresholds .................................................................................. 85

Table 13-1: Calibrating battery current measurements..................................................... 98

Table 14-1: Time displays................................................................................................... 100

Table 14-2: Main dip switch statuses ................................................................................ 100

Table 14-3: Panel and slave dip switch statuses ............................................................. 101

Table 14-4: Controller external and internal power statuses..........................................101

Table 14-5: System temperature displays......................................................................... 101

Table 14-6: Battery test information.................................................................................. 103

Table 15-1: Technical specifications................................................................................. 105

Table 16-1: Ordering parts..................................................................................................106

Power+ Technical Guide

vii

Gamatronic Electronic Industries Ltd.

WARNING: RISK OF
SEVERE DAMAGE TO THE UPS!!!

THIS SYSTEM USES THE NEUTRAL LINE FOR

OPERATION

. THEREFORE, IT IS STRICTLY

FORBIDDEN TO CONNECT THIS SYSTEM TO

THE

AC POWER SOURCE WITHOUT A NEUTRAL

(NULL) CONDUCTOR!!

AILURE TO USE A NEUTRAL CONDUCTOR MAY

F

CAUSE PERMANENT DAMAGE TO THE SYSTEM

IN THE EVENT THAT SYSTEM OUTPUT CAPACITY IS INCREASED ABOVE THE
ORIGINAL FACTORY CONFIGURATION, THE SYSTEM NAMEPLATE MUST BE
UPDATED TO INDICATE THE NEW POWER AND CURRENT CAPACITY.
This condition applies when new, non-redundant power modules are added to the
system or when formerly redundant modules are designated as non-redundant.

.

viii

Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

r

t

T

r

1. SYSTEM STRUCTURE

The Power+ is a parallel redundant UPS. A block diagram is shown in Figure 1-1 below.

System
Controller

RS232, TCP/IP, Cellular,

Bypass Powe

Mains Powe

UPS

10KVA

UPS

10KVA

UPS

10KVA

UPS

10KVA

Static Switch

Isolation

ransformer

(optional)

Outpu

Centralized

Figure

1-1: Block diagram

Power+ Technical Guide 1

Gamatronic Electronic Industries Ltd.

The system comprises the following sub-assemblies.

1-10 UPS modules × 10kVA (4 in the example in Figure 1-2 below)

System Controller

Static Switch Module

Power Distribution Block

Figure 1-2: Sub-assemblies

Figure 1-3: 10kVA configuration

2 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure 1-4: 50kVA configuration

Figure 1-5: 100kVA configuration

Power+ Technical Guide 3

Gamatronic Electronic Industries Ltd.

2. FUNCTIONAL OVERVIEW

2.1 UPS BASIC MODULE (10KVA / 8KW)

The UPS Basic Module is the core of the system, which comprises 1 to 10 identical parallel
modules depending on capacity requirements.

A general module view is shown in
type block diagram is illustrated in

Figure 2-1. The module classic on-line double-conversion

Figure 2-2.

This design has proved to be very stable. No transfer time is required for the UPS to switch
from normal to backup mode; the load is supplied constantly by stable and clean power. A
Power Factor Correction (PFC)

1

is responsible for the low Total Harmonic Distortion (THD) and

unity Power Factor (PF) at the input.

The input voltage(s) is converted to a stable ±425V at the DC link.

This stage can maintain current sharing between the three input phases as well as among
other parallel units, because of the current sharing signal that it produces.

Figure 2-1: Single UPS Module- Front/Rear View

1

PFC is a feature included that reduces the amount of generated reactive power. Reactive power
operates at right angles to true power and energizes the magnetic field. Reactive power has no real
value for an electronic device, but electric companies charge for both true and reactive power resulting in
unnecessary expense.
In power factor correction, the power factor (represented as "k") is the ratio of true power (kwatts) divided
by reactive power (kvar). The power factor value is between 0.0 and 1.00. If the power factor is above

0.8, the device is using power efficiently. A standard power supply has a power factor of 0.70–0.75, and
a power supply with PFC has a power factor of 0.95–0.99.

4 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure 2-2: Block diagram of a single UPS Module

Power+ Technical Guide 5

Gamatronic Electronic Industries Ltd.

The PFC power section block diagram is shown in Figure 2-3. Input currents of the PFC

(without filters) is shown in

Figure 2-4; the control scheme is illustrated in Figure 2-5.

+

Ir

R S

Control

Is

Control

It

T

Control

-+

-+

-+

N

Figure 2-3: Power section of the PFC in a single UPS module

+

Ipeak

Ir Is

(CCM)

t

-Ipeak

Figure 2-4: Input currents of the PFC (without filters)

As shown in Figure 2-3, the PFC section operates in Continuous Current Mode (CCM)

conduction, which has many advantages. Input currents are shaped in such a way that they
follow the input voltages with precision.
This makes the system appear to be nothing more than a resistive load with respect to the line
voltage. In other words, the system corrects the input current waveform of the connected load,
and acts as an active power filter.
The PFC section also draws symmetrical currents from each phase, and maintains good
current sharing among identical UPS modules in parallel.

Each phase input is sensed for voltage and current, required to force the input current drawn
from the phase input to follow its voltage and emulate a resistor. Two feedback loops are

It

6 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

required for the proper operation, an inner current loop for maintaining a correct wave shape
and an outer voltage loop to ensure a correct DC output level.

The voltage sample (k*Vin) is multiplied by the error voltage from a common voltage feedback
amplifier (Integrator). The result is than compared to the actual sampled phase current which
forces the current amplifier current to follow the phase input voltage. The output of the
integrator is connected to a current sharing bus causing all other modules to be connected to
this bus via the same resistor. This ensures that all the multipliers of each UPS module receive
the same input and all that modules are equally loaded.

PH1

NEUTRAL

PH2

NEUTRAL

K1*V1

K1*V2

MULT

MULT

Current
Amplifier

+

-

Current
Amplifier

+

-

Comparator

+

-

Triangle

Comparator

+

-

Triangle

PWM

PWM

POWER
BLOCK

POWER
BLOCK

Vout (DC)

Current
Amplifier

+

-

Integarator

Comparator

+

-

Triangle

-

+

PWM

Vref

POWER
BLOCK

K2*Vout

PH3

NEUTRAL

MULT

K1*V3

Verror

DC
share
bus

Figure 2-5: PFC control scheme

Power+ Technical Guide 7

Gamatronic Electronic Industries Ltd.

The second stage of the UPS module is the DC/AC inverter.

This stage is fed by the DC symmetrical voltage produced by the PFC stage which then it
inverts to create clean sinusoidal output(s).

POWER+ employs “3-L” (3-level) topology which achieves very high efficiency (over 96%)
which in turn enhances the overall AC-AC efficiency of the entire system.

As shown in

Figure 2-6 the inverter voltage is produced using three levels of DC voltage (unlike

standard two-level system).

The POWER+ inverter uses Insulated Gate Bipolar Transistors (IGBT) as efficient high
frequency switches.

Apart from the AC/DC PFC and DC/AC inverter each UPS module also contains a digital
controller, responsible for all the control mechanism and all communications with other modules
of the system.

Each UPS module also provides the system controller with a report related to its condition and
operation status. All the data available from all modules is displayed on an LCD display.

The UPS module is cooled using forced convection. The fan varies with the load level, making
for improved reliability, reduced noise, and less dust is introduced.

+

L
L
L

Vr
Vs
Vt

C

-+

-+-+

C

C

N

+

Control

Figure 2-6: DC/AC inverter principal topology

8 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

2.1.1 SINGLE UPS MODULE SPECIFICATIONS

2-1 Single UPS Module Specifications

Table

TECHNICAL DATA – UPS MODULE

Output Rated Power 10 kVA / 8 kW
Topology Online Battery, Double Conversion
Construction Modular parallel hot-plugged modules
Input Voltage (V) 3 × 400+N (3 × 230 V)
Input Voltage range (%) -27 and +20
Input Current (A) 15 A
Input Frequency (Hz) 47–63 Hz
Frequency tracking range (Hz) ±1, ±2, ±3 (selectable)
Output slew rate 1 Hz/sec
Power walk-in (sec) > 60
Input Power Factor 0.99
Input THDI (%) 5
Output Voltage (V) 3 × 400+N (3 × 230V)
Output Static Regulation (%) ±1
Output Regulation for unbalanced load (%) ±1 for 100% unbalanced load
Dynamic response to 100% load step (%) 2

110 % for 10 minutes

Overload

Output Waveform Sinusoidal
Output THD (%) Less than 2 for linear load
Load CF (max) 6:1
Fuse clearance capability Input, Output, DC link
AC-AC efficiency (nominal) Up to 96 at full load
Maximum power dissipation (Po=8KW) 421 W (1437 BTU)

Ambient temperature (ºC)

Relative humidity (%) 95 max non-condensing
Altitude (m) 1500 w/o de-rating
DC-Link Voltage ±340 V to ±425 V
Cooling system Forced air: multi-fan with speed control
Dimensions: W x H x D 19" x 2U x 455 mm (Excluding shelf)
Weight 9.5 Kg

125 % for 60 seconds
1000 % for 1 cycle

-10 to +40 (operating)

-20 to +60 (storage)

Power+ Technical Guide 9

Gamatronic Electronic Industries Ltd.

2.2 UPS SYSTEM CONTROLLER

The POWER+ system controller is designed primarily for monitoring, diagnostics and
communications.

Some other useful features include temperature compensation of the battery voltage.

The POWER+ can work without the system controller but with reduced functionality.

Figure 2-8 shows the system controller block diagram. The core of the controller is a powerful

embedded micro-controller, surrounded by many peripherals (analog, digital, communication).

The controller front panel is shown in

Figure 2-7: System controller - Front panel

Figure 2-7.

10 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure 2-8: System controller - Block diagram

Power+ Technical Guide 11

Gamatronic Electronic Industries Ltd.

2.2.1 SYSTEM CONTROLLER SPECIFICATIONS

Table 2-2: System controller specifications

TECHNICAL DATA – SYSTEM CONTROLLER

Micro Controller core 16 bit
Display 4 x 40 characters LCD with backlight
Other indicators 8 LED’s, buzzer
Analog input channels 4
Digital input channels 8
Real Time Clock (RTC) Yes, with backup
Power meter kVA, kW, PF
Voltage-free outputs (dry contacts) 6
RS232 user port Yes, isolated
Optional communication TCP/IP, GPRS/SMS Wireless

communication (Optional)
Communications with system modules Serial, isolated
Events log 255 events
System operation without controller Unchanged
On-screen parameters Load bar-graph

3-phase voltages

3-phase currents

Battery voltage

Status of each UPS module

Static-switch parameters and status

Battery sensor temperature
Alarms AC abnormal

DC abnormal

UPS module(s) failure

Load on bypass

Battery test failed

Over/under temperature

Overload
RTC operation without power 2 weeks
Power requirements 12V±10%, 1A via 2.1mm phono jack

2.3 STATIC SWITCH (ST/SW) MODULE

The static switch module is used for overriding the input to output in case of a system failure or
heavy load start or if specifically requested by the user.

The module receives two AC inputs and supplies only one.

Generally the ST/SW connects the output of the paralleled UPS modules to the main output of
the system. However, if the modules fail to provide an adequate voltage for a determined time,
i.e. detection time, the ST/SW module instantly switches to the alternative power source, that is
the AC input, as illustrated in
purpose using a combination of fast semiconductors and an electromechanical relay.
The module monitors all the inputs in real time to determine the method of operation. The
ST/SW module’s front panel is shown in

12 Power+ Technical Guide

Figure 2-10. The unit employs an efficient AC switch for this

Figure 2-9.

Gamatronic Electronic Industries Ltd.

Figure 2-9: ST/SW front panel view

Figure 2-10: ST/SW block diagram

Power+ Technical Guide 13

Gamatronic Electronic Industries Ltd.

INV

INV

INV

B

Outputs

Monitoring & Control

BP

BP

BP

Figure 2-11: 3-Phase ST/SW block diagram

14 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3. SYSTEM INTERCONNECTION

The POWER+ system comprises UPS Modules, a System Controller, Static Switch and
distribution elements such as AC, DC and fuses. These components are assembled as shown
in

Figure 3-1.

A major advantage of the POWER+ is its upgradability simply by adding UPS modules and
shelves as required.

The system controller occupies the same space as the UPS module and although not critical, is
most often mounted at the top shelf for convenience. This permits easier viewing of the display.
The static switch module however, is always mounted at the bottom of the system (see

3-1).

Figure

Figure 3-1: Power+ system - Modular structure

Power+ Technical Guide 15

Gamatronic Electronic Industries Ltd.

3.1 INTERNAL SYSTEM WIRING

The cabling and wiring of a 30kVA Power+ system are illustrated in schematics in Figure 3-2

(single-phase output) and

Figure 3-3 (3-phase output) below.

Figure 3-2: Schematic of a 3:1 Phase 30kVA POWER+ System

Note: For use with single-phase input, all 3 phases of each AC input are connected together
internally inside the cabinet. REFER TO SINGLE-PHASE OUTPUT INSTRUCTIONS.

16 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure 3-3: Schematic of a 3-Phase 30kVA POWER+ System

Cables for the POWER+ are all connected at the rear of the system.

Cables are routed between the UPS modules system controller and static switch – down to the
AC and DC distribution sections that are mounted at the bottom of the rack.

Figure 3-1 shows

the rear view of the POWER+ system. (Note that 3 UPS modules are in use in this illustration).
UPS modules are numbered from bottom to top; i.e. the lowest UPS module is "UPS #1"; the
UPS above it is "UPS #2" and so on.

Power+ Technical Guide 17

Gamatronic Electronic Industries Ltd.

Figure 3-4: POWER+ System - Rear View

18 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

UPS modules are inter-connected by a flat cable which is used for the transmission of digital
and analog data.
This data is essential for maintaining synchronization and current sharing between modules.
This flat cable is connected to a small PCB in the UPS shelf and is connected to the control
DIN48 connector described on page

24.

NOTE:

PROPER CONNECTION OF THE FLAT CABLE

IS OF CRITICAL IMPORTANCE.

INCORRECT OR WEAK CONNECTION

WILL PREVENT THE SYSTEM FROM OPERATING.

Each shelf has a digital address that is preset at the factory and determined by the DIP switch
mounted on the small control board as shown in

Figure 3-5.

Figure 3-5: Control PCB and flat cable

Power+ Technical Guide 19

Gamatronic Electronic Industries Ltd.

3.1.1 THE POWER+ ALWAYS REQUIRES A NEUTRAL LINE

During both installation and operation of the Power +, a neutral line must always be connected
to the UPS. This neutral line shall be connected during the entire period that the UPS is
working, and shall not be disconnected at any time!

Caution: If at any time the neutral line becomes disconnected, there will be no input or output

reference voltage, because the input neutral line and the output neutral line are physically
linked together. That may result in system defining its own reference voltage, which will be set

by the load distribution between the three phases. This can result in serious damage to the

UPS.

A 4-pole switch might disconnect the neutral line

WARNING! If you have a mains-to-generator four-pole switching system you are in danger of
having the neutral line disconnected when the four-pole switch is operated. This can result in

the problems described above.

To avoid these problems, we strongly recommend that, if you use a four-pole mains-to­generator switching system, you install an isolation transformer that will constantly provide the
UPS with a neutral line.

Figure 3-6 on page 21 illustrates the wrong way to connect the UPS with a grounded-neutral

generator.

Figure 3-7 on page 22 illustrates an acceptable connection solution if you already have a

grounded-neutral generator.

Figure 3-8 on page 23 shows the preferred generator (neutralized, not grounded) and the

preferred connection (three-pole).

20 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure

Power+ Technical Guide 21

3-6: Wrong way to connect UPS with grounded-neutral-generator

Gamatronic Electronic Industries Ltd.

Figure

22 Power+ Technical Guide

3-7: Acceptable connection for grounded generator and 4-pole switch

Gamatronic Electronic Industries Ltd.

Figure 3

Figure

Power+ Technical Guide 23

3-8: Preferred generator (neutralized) and connection (3-pole)

Gamatronic Electronic Industries Ltd.

3.1.2 UPS MODULE – CONNECTORS DESCRIPTION

The UPS module includes three connectors (see Figure 3-9) on the rear panel. Two 15-pin DIN

connectors (“DIN15”) are for power connections and one 48-pin (“DIN48”) DIN connector for
signaling and control.

WARNING

ALL THE CONNECTOR PINS CARRY HAZARDOUS VOLTAGES

ALWAYS AVOID ACCESS TO THESE PINS!

Input Connector

(15-Pin DIN)

Output Connector

(15-pin DIN)

Figure 3-9: UPS module – Rear view

The connectors pin assignments are illustrated in
below.

30

32

26 22

28

18

14

24

"DIN 15" CONNECTOR

20

16

12

10

Control Connector

(48-Pin DIN)

Figure 3-10 and described in Table 3-1

bac

1
2
3
4
5

6

84

6
7
8

9
10
11
12
13
14
15
16

b 8

"DIN 48" CONNECTOR

Figure 3-10: UPS module connectors - Pin assignments

24 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3.1.3 UPS MODULE PIN ASSIGNMENT TABLE

WARNING

THE DATA PROVIDED BELOW IS FOR INFORMATION ONLY.

DO NOT ATTEMPT TO MAKE ANY CONNECTIONS.

Table 3-1: UPS module pin assignment and function

Input Connector

4 = (-425V) 6 = (-425V) 8 = (-425V) 10 = Neutral 12 = Neutral

14 = T phase 16 = T phase 18 = S phase 20 = S phase 22 = R phase

24 = R phase 26 = Neutral 28 = (+425V) 30 = (+425V) 32 = (+425V)

Output Connector

4 = OUT3 (T) 6 = OUT3 (T) 8 = OUT2 (S) 10 = OUT2 (S) 12 = OUT1 (R)

14 = OUT1 (R) 16 = N.C. 18 = N.C. 20 = N.C. 22 = Neutral

24 = Neutral 26 = Neutral 28 = N.C. 30 = N.C. 32 = N.C.

Control Connector

"a" Column "b" Column "c" Column

1 = System Controller Com 1 = Controller TX 1 = Controller RX

2 = Dry2_opto_E 2 = N.C. 2 = N.C.

3 = Dry2_opto_C 3 = N.C. 3 = N.C.

4 = N.C. 4 = N.C. 4 = N.C.

5 = N.C. 5 = N.C. 5 = N.C.

6 = DRY 0 6 = UPS OFF 6 = Vout_Sum

7 = DRY 1 7 = CAN BUS 7 = WANT

8 = +12V BUS 8 = Stand Alone 8 = Vcc (+5V)

9 = Force B/P Inv 9 = AC on INV 1 9 = Address Com.

10 = Common BUS 10 = Common BUS 10 = Common BUS

11 = Dry 2 11 = Device Address (#3) 11 = PLL DATA BUS

12 = Reference Frequency 12 = Device Address (#2) 12 = PLL SYNC BUS

13 = SPI Select 13 = Device Address (#1) 13 = Sharing BUS (S)

14 = MIS 0 14 = Device Address (#0) 14 = Sharing BUS (R)

15 = MIS 1 15 = +12V BUS 15 = Sharing BUS (T)

16 = SPI_SCK 16 = Address Common 16 = +12V BUS

Power+ Technical Guide 25

Gamatronic Electronic Industries Ltd.

Legend

N.C. = Not Connected (Unused)

PLL = Phase Locked Loop (Synchronization system)

Sharing = Current Sharing circuit (Among modules)

Device Address = Identifies the location of a UPS module within the system

WANT / CAN = Signals related to the parallel mechanism

3.2 DC DISTRIBUTION PANEL CABLING

WARNING

BATTERY CABINETS MAY BE CONNECTED AND

MAINTAINED BY A QUALIFIED TECHNICIAN ONLY!!!

NOTE:

The Neutral line is common to the input and

output as well as to the battery "0V" point!

The DC distribution panel is located at the bottom of the system on the rear, below the first
UPS module (”UPS #1”).

This panel receives the DC wires from the system’s UPS modules and from the controller, as
well as from internal or external battery cabinets.

The DC voltages are very high and dangerous (± 425Vdc).

External battery connections are performed at the right side of this panel.

The DC distribution panel on your system will have one of two possible layouts, depending on
whether your system has a maximum capacity of 50KV or 100KV. maximum capacity, as
shown in

Figure 3-11.

The Anderson connector plugs on the DC distribution panel are color coded: RED=positive,
BLACK=negative, BLUE=neutral.

Refer also to

26 Power+ Technical Guide

Figure 6-3 on page 68 for battery connection details.

Gamatronic Electronic Industries Ltd.

Figure 3-11: DC distribution panel (50KVA model)

Figure

3-12: DC distribution. panel (100kVA model)

Power+ Technical Guide 27

Gamatronic Electronic Industries Ltd.

3.2.1 DC FUSES

All DC fuses are located on the opposite side (the front side) of the DC distribution panel. There
are two fuses for each power module and for the controller – one for the positive line and one
for the negative line.

Figure 3-13 and Figure 3-14 show the assignments.

Figure 3-13: DC fuses on front side of DC dist. panel (50KVA model)

Figure 3-14: DC fuses on front of DC dist. panel (100KVA model)

28 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3.3 AC INPUT FUSES

The input of each UPS module is protected by a 15A fuse for each phase, so that each module,
including the controller, has 3 fuses (for R, S, T phases). 10 modules plus the controller would
require 33 fuses, as illustrated in
i.e. the 3 fuses on the far right protect UPS #1.

Figure 3-15. Fuse receptacles are numbered from right to left,

Figure 3-15: UPS modules - AC input fuses (100KVA model)

WARNING

ALWAYS REPLACE FUSES WITH THE SAME TYPE AND RATINGS !!!

Figure 3-16: AC input fuse assignments (50KVA model)

Power+ Technical Guide 29

Gamatronic Electronic Industries Ltd.

3.4 AC DISTRIBUTION COMPARTMENT

The AC distribution compartment (Figure 3-17) distributes AC voltages to and from the UPS

modules and is located on the rear of the UPS, below the DC distribution panel. Connections
are as shown below.

The AC input to the modules are protected by the AC fuses as described above.

Figure 3-17: AC distribution

Figure

Figure

3-18: AC distribution panel (100KVA model)

3-19: AC distribution panel (50KVA model)

30 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3.5 AC INPUT/OUTPUT MAIN TERMINALS

The main terminals section is critical for system installation. The terminals are used to connect
the AC inputs and AC output to the mains electricity cabinet. The terminals section is illustrated
in

Figure 3-20. The installation procedure is detailed in Section 4.

NOTE:

The Neutral line is common to the input and

output as well as to the battery "0V" point!

Figure 3-20: Input & output main terminals

Power+ Technical Guide 31

Gamatronic Electronic Industries Ltd.

3.6 STATIC SWITCH CONNECTIONS

The static switch’s internal connections include two AC inputs and one AC output.
As shown in
separate terminal is dedicated for the Neutral line (which does not carry current) and is used for
measurements.

This module communicates with the rest of the system via the communication port located at
the right side of the unit.

Additional terminals are provided as shown for Emergency Power-Off (EPO) and for Load On
Bypass indication.

Figure 3-21, three groups of terminals are located accordingly on top of the unit. A

Figure 3-21: Static switch terminals – Rear view

32 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3.7 SYSTEM CONTROLLER CONNECTIONS

The controller is typically located in the top housing shelf of the UPS for easier access.

Although the UPS modules reads their digital address number from the Control PCB (discussed

later) the controller does not

Connections to the System Controller are from the rear, as shown in Figure 3-22.

!

NOTE:

Several Controller options are available

(e.g TCP/IP, cellular and more).

Refer to your dealer for further details.

Figure 3-22: System controller outside the shelf - Rear view

3.7.1 PC714 – THE CONTROLLER CARD

The PC714 card contains the logic chips that perform the UPS controller functions. PC714 also
contains the LCD display screen, and several jumpers, the usage of which are explained below.

Figure 3-23 shows the front side of the PC714 card, Figure 3-24 shows the rear side. Figure
3-25 shows the location of the jumpers on the rear of the card, and

function of the jumpers. (See also section
status on the controller screen.)

To reach the PC714 card it is necessary to remove card PC575.

The controller's flash memory resides on PC714. Instructions for replacing the flash memory
are in section

Power+ Technical Guide 33

12.4 on page 93.

11.4.4 on page 89 for how to display the jumper

Table 3-2 explains the

Gamatronic Electronic Industries Ltd.

3-23: Front side of PC714 card

Figure

Figure

3-24: Rear of PC714 – white rectangle indicates jumper area

Figure

34 Power+ Technical Guide

3-25: The jumpers on PC714

Gamatronic Electronic Industries Ltd.

3-2: Jumpers on PC714

Table

JUMPER DESCRIPTION

This jumper should be in place only the first time the UPS is started up, before the UPS has

JP1

JP2

JP3

JP4,

JP5

been configured. When this jumper is in place, the UPS used fixed internal "factory default"
configuration values. Once you have configured the UPS this jumper should be removed.

When in place, the UPS operational parameters can be updated.
When not in place, the UPS parameters cannot be changed.

This jumper affects the entry of the battery capacity parameter in the "Setups > Battery" option.
When the jumper is in place, a capacity from 10 to 890 amp/hrs can be specified.
When the jumper is removed, a capacity from 10 to 89 amp/hrs can be specified.

These two jumpers should normally always be in place. When in place they enable the UPS to
communicate with the network board PC575, which in turn interfaces with the "outside world"
(the network) via the RS232 interface. JP4 enables signal transmission, JP5 enables signal
reception.

JP6

JP9

When this jumper is removed, the remote control panel can be used.

When this jumper is in place, the UPS expects 220/230 Vac input.
When this jumper is removed the UPS expects 110/120 Vac input.
(Note that the jumper status screen [main menu, down arrow, down arrow] displays only 110 or
220 to indicate the status of JP9, but the acceptable voltages are as stated above, insofar as
jumper JP9 is concerned.)

Power+ Technical Guide 35

Gamatronic Electronic Industries Ltd.

3.8 SETTING THE SHELF ADDRESS

Each UPS module shelf – including the controller module shelf – has a digital address that can
be accessed by the module once it has been initialized. The module addresses are used to
identify each module during the normal operation and monitoring of the system.

No two shelves can have the same address. The address is related to the physical location of a

specific shelf, and is preset at the factory by the “Module Location” DIP switch mounted on

the control PCB. (See
address of the newly added shelf must be set correctly.

The control PCB contains an additional DIP switch – the “Master/Slave” DIP switch – that is

used to indicate which of the UPS modules is the “Master”, and which UPS modules are the
“Slaves”. Only one UPS module is designated as “Master”; all of the other UPS modules are
“Slaves”.

Figure 3-26). When adding a new module to an existing system, the

Figure 3-26: The PC917 Control PCB on a shelf – general view

36 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure 3-27: DIP switches on PC719 card– close-up

Figure 3-27 shows the DIP switches on the PC719 card, which is located on the back of each

shelf housing a UPS or the controller module.

Master/Slave DIP Switch Settings

The two DIP switches on the left determine which UPS will be the “master” UPS. Best practice
is to make UPS#1 (the first UPS) the master, and let the others be slaves.

Figure 3-28: Recommended master/slave DIP switch settings

Power+ Technical Guide 37

Gamatronic Electronic Industries Ltd.

“Module Location” DIP switch Settings

In the example shown the “FIRST UPS” DIP switch is set as follows:

1= "on", 2= "on", 3= "on", 4="on”, indicating UPS #1. See

Table 3-3: DIP switch setup in a 100kVA system (X = don't care).

Table 3-3 below and FIGURE 3-29.

Figure 3-29: DIP switch settings

Lowest Module Select (LMS) jumper: The first module (UPS #1) must be assigned as such

by a jumper on the MOLEX-2 connector.
Other versions of the Control PCB may have a 2 level DIP switch instead of this connector, in
which case both switches must be ON.

38 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3.9 F.A.Q. (FREQUENTLY ASKED QUESTIONS)

3.9.1 BATTERIES

3.9.1.1 Q: WHAT IS THE DC VOLTAGE OF THE SYSTEM? HOW MANY BATTERIES ARE

NEEDED

A: The nominal DC voltage of the system is ±424v to ±432. Power Plus units operate with positive and
negative voltage independently. There are 64 batteries in series in each battery bank, with a middle
connection point which has additional wire connected, so there are two groups – positive and negative,
32 batteries in each. The DC voltage is measured between the center point and one of the poles. The
middle point is interconnected with the input neutral. If the DC voltage is measured between the positive
side and the negative side, it will be in range of 848v to 864v DC.

3.9.1.2 Q: WHY SHOULD THE BATTERY CAPACITY BE ENTERED IN THE SYSTEM

CONTROLLER

A. The battery capacity has to be entered for the calculation of the battery test duration. Power Plus units
offer smart battery handling, and one of the features is a smart battery test. It uses the relevant
information to provide the best information about the current battery status. This information includes
global battery Ah rating, current load level, battery current (if available) and some calculations.

?

?

3.9.1.3 Q: WHAT WILL HAPPEN IF THE BATTERY CAPACITY WAS NOT SETUP

CORRECTLY

A. Accurate values of Ah battery capacity should be entered; otherwise the reliability of the smart battery
test will be lower.

?

3.9.1.4 Q: WHY DOES MY BATTERY TEST LAST FOR MORE THEN 1 MINUTE?

A. Battery test can last for a number of minutes, it is not a problem. For a unit with large batteries and low
load, checking the battery condition in the best way will take more then one minute. Power Plus units
have smart battery test feature implemented, which discharges the batteries by 5% of the capacity during
the test to check them in the best way.

3.9.1.5 Q: WHAT IS THE MAXIMUM CHARGING CURRENT FOR THE BATTERIES?

A. Under full load each module can provide 2 A to charge the batteries. In case that a module is not
loaded, the entire rectifier current (12 A) can be passed to the batteries. Another example, if one module
is loaded at 50% on the output it can provide around 7 A to the batteries. This means that in Gamatronic
systems with on-line battery topology all current that doesn’t go to inverter is available for battery
charging.

3.9.1.6 Q: SHOULD THE BATTERY CURRENT LIMIT FEATURE BE ACTIVATED?

A. The battery current limit is an optional feature. Before enabling it please make sure that you have this
option in the system. In order to check it, please see the rear side of the controller. There are three
battery current sensors connections there, in a green plug. If nothing is connected there, then this option
is not available in your system and must be disabled.

Power+ Technical Guide 39

Gamatronic Electronic Industries Ltd.

3.9.1.7 Q: WHY SHOULD I USE THE BATTERY CURRENT LIMIT? IF I ACTIVATE IT, WHAT

PARAMETERS DO

A. Correct parameters for battery current limit are specified by a battery manufacturer, in a datasheet. It
improves the battery lifetime and protects from overcharging. Caution: Incorrect setting might cause
unexpected system operation.

I USE?

3.9.1.8 Q: SHOULD THE BATTERY TEMPERATURE COMPENSATION BE ACTIVATED?

A. The battery temperature compensation is an optional feature, which consists of a temperature sensor
with wires for specified length for external or going into the unit for internal batteries. It connects to the
rear side of the controller, to a green plug with its own specific connection. Before enabling this feature,
make sure you have it in your system.

3.9.1.9 Q: WHY SHOULD I USE THE BATTERY TEMPERATURE COMPENSATION? WHAT IS

THE CORRECT VALUE

A. The battery temperature compensation should be corrected according to the battery manufacturer’s
recommendations; it protects the batteries form overcharging in a high temperature environment.

?

3.9.1.10 Q: WHEN THE AH VALUE FOR THE BATTERIES IS ENTERED, AND THERE ARE TWO

OR THREE BATTERY CABINETS SELECTED
VALUES OR DIVIDE THEM BETWEEN THE CABINETS

A. If the number of battery cabinets is set to more than one, then you will have to select the battery Ah
rating for each battery cabinet independently, as it can be different. Eventually the unit will add these
values and obtain the global Ah value.

, WILL THE UNIT ADD THE ENTERED

?

3.9.2 GENERAL

3.9.2.1 Q: DOES POWER PLUS UNIT HAVE EQUALIZING (BOOST CHARGE) MODE?

A. Gamatronic UPS systems do not use equalizing (boost) battery charging. If you have equalizing menu
entry in your controller menu, please arrange software version upgrade for your controller.

3.9.2.2 Q: WHAT WILL HAPPEN TO THE UNIT IF THE SYSTEM CONTROLLER IS REMOVED?

A. When the controller is removed, the system will continue with normal operation, including battery
charging and backup operation upon power failure. It will also start normally when mains power is turned
on.

3.9.2.3 Q: CAN I USE THE SYSTEM WITHOUT SYSTEM CONTROLLER MODULE AT ALL?

A. Yes, the UPS system will provide the basic functionality; however, many important features will not be
available. Major features include battery test, measurements, control etc. Without a system controller the
system will function as a rectifier, batteries and an inverter (with ST/SW) only with no additional features.
This kind of operation is not recommended.

3.9.2.4 Q: HOW CAN THIS SYSTEM WORK AS A SINGLE AND TRIPLE PHASE (SELECTABLE) ON THE INPUT?

40 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

A. This unit features advanced rectifier technology which allows you to connect triple phase voltage to
the inputs or just a single phase linked together on R (L1), S (L2) and T (L3) inputs. The unit will accept
both connection types on the input, no additional settings are needed.

3.9.2.5 Q: HOW CAN THIS SYSTEM WORK AS A SINGLE AND TRIPLE PHASE (SELECTABLE) ON THE OUTPUT?

A. The special inverter function allows single phase output operation. To switch the system to single
phase operation, each UPS module should be removed while the system is off and its dip switch number
3 (they are located in a small window on the left side of each module) should be moved to the OFF
position (ON for 3 phase output operation). Then the output phases R (L1), S (L2) and T (L3) should be
linked altogether to a single phase wire output (used with the output neutral), as the phase angle will be
switched to 0

0

and each module will have its inverters operating in parallel.

3.9.2.6 Q: HOW CAN THIS SYSTEM BE SWITCHED TO 60HZ OUTPUT?

A. The unit will auto-detect input frequency and have same frequency on the output. To switch the
system to 60Hz output operation manually, each UPS module should be removed while the system is off
and its dip switch number 2 (they are located in a small window on the left side of each module) should
be moved to the on position (off for 50 Hz or auto-detect output operation).

3.9.2.7 Q: HOW WILL THE ST/SW MODULE REACT TO A CHANGE FROM TRIPLE TO

SINGLE PHASE AND VICE VERSA ON THE OUTPUT

A. The bypass input of the unit should fit the output voltage. If the output voltage is triple phase, then the
bypass input should be triple phase as well. If the output is single phase, and the output phases are
linked altogether, then the same thing should be done with the bypass input of the unit – one phase
connected and the R (L1), S (L2) and the T (L3) inputs of the bypass linked altogether. The ST/SW
module will detect it and function as a triple or single phase unit automatically.

?

3.9.2.8 Q: DOES THIS UNIT HAVE DRY CONTACT OUTPUTS, AND FOR WHAT ALARMS?

A. These systems have 6 dry contacts on the controller’s rear panel. Two of them are in a DB9
connector (pins 3, 4 alarm no. 1 and pins 5, 4 alarm no. 2). The other four are located in a marked wide
green connector with screw wire attachments. There are N.O., N.C. and the COMMON connections for
each dry contact. All dry contacts are programmable through the controller, selectable from the global list
of 32 alarms. Any number of alarms can be set for any dry contact. All the contacts are rated at 24V 1A.

3.9.2.9 Q: DOES THIS UNIT HAVE INPUT DRY CONTACTS?

A. There are 4 input normally closed dry contacts, located in specific green plug on the rear side of the
system controller. As a standard they are all linked to the common on the plug, and provide no alarms.

3.9.3 MENUS

3.9.3.1 Q: WHAT IS THE ALARM “HYSTERESIS” SETTING?

A. The voltage alarm hysteresis is the value of voltage difference for finalizing the alarm. For example, if
the alarm value is 245v and the hysteresis is 5v, then when the voltage grows above 245v and the alarm
will activate, it will end only when the voltage drops below 240v.

3.9.3.2 Q: WHAT IS THE “INTEGRAT.” MENU ENTRY?

A. The “Integrat.”, which is the integration factor, is a value for confirming the internal RS232
communications. This option should not be changed usually and is preset for optimal performance.

Power+ Technical Guide 41

Gamatronic Electronic Industries Ltd.

3.9.3.3 Q: WHY SHOULD I USE THE INDIVIDUAL UPS MODULE TURN ON/OFF FEATURE?

A. The individual UPS turn on/off feature is disabled.

3.9.3.4 Q: WHY ARE THERE TWO SETTINGS FOR A NUMBER OF UPS MODULES IN THE

SYSTEM

A. A total number of modules represent the units with which the controller will communicate and monitor.
The redundancy number of modules shows how many units are functioning as a backup, without being
calculated in a global load level of the system. For example, if you have a 30KVA unit with a setting for 1
redundant module, when the output load will reach 20KVA the unit will show a full load condition. It will
still not switch to bypass, but will alarm you with overload if the output load will rise above 20KVA. For
the user this means that the unit does not have the redundancy anymore under this load. If the
redundant modules value is set to 0, then a 40KVA unit will function as a standard unit of 40KVA output
load maximum. It you set this parameter to 3, the same unit will have a load bar-graph of a 10k system
and will alert the customer with overload when there is more then 10k of load on the output.

?

3.9.3.5 Q: WHAT IS THE DC-I OFFSET REMOVAL AND THE DC-I CALIBRATION MENU

ENTRIES

A. The DC-I offset removal and the DC-I calibration should be performed only if the battery current
measurement is not correct. It is being used on new controllers only upon current sensors connection.
You might have do use these features if adding current sensors on a later stage. To perform it the unit
should work without a load and with batteries disconnected. Then the offset removal should be
preformed (only if the measurement current is not zero) and then the unit should be connected to some
load and batteries and operated in input power failure mode. Then the actual current is being measured
and corrected live in the controller using the calibration menu entry.

?

3.9.4 INSTALLATION

3.9.4.1 Q: DOES THE UNIT HAVE EPO (EMERGENCY POWER OFF) CONNECTION?

A. Yes. The connection is on the ST/SW module. Unscrew two mounting screws on the front panel of the
ST/SW module and slightly pull it out. The EPO connection is on its top.

3.9.4.2 Q: WHEN THE EPO IS DEACTIVATED, THE UNIT STILL WON’T RETURN TO

NORMAL OPERATION

A. When the EPO function was activated, the unit stopped functioning and provided voltage to battery
breaker trip coil (option of the battery cabinet) to switch the batteries off as well. To restore normal
operation of the UPS system, it should be completely restarted.

3.9.4.3 Q: UPON THE INSTALLATION, THE UNIT WON’T SWITCH TO INVERTER AND THE
“SYNC” LED ON ST/SW MODULE IS IN RED. EVERYTHING ELSE IS OK. WHY IS

THAT

?

A. Usually this means that the phase sequence on the ST/SW input (the bypass) is not correct. These
units get synchronized on the bypass and therefore check the phase sequence there. Swapping phase S
(L2) and T (L3) on the bypass input should correct the situation.

3.9.4.4 Q: WHEN I PRESS THE INV/BYP BUTTON ON THE ST/SW MODULE, IT DOESN’T

SWITCH TO

A. The Inv/Byp button is a press and hold button for protection. It should be held for a number of seconds
until the alarm LED lights in green, and then released. There is the same button on the controller; there it
should be pressed twice to initiate a manual transfer.

/FROM BYPASS. HOW DO I DO THE MANUAL TRANSFER?

. WHY IS THAT?

42 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

3.9.4.5 Q: DOES THIS UNIT HAVE DUAL INPUTS?

A. Power Plus systems, as any other standard Gamatronic systems above 10Kva, use dual inputs,
meaning independent input for the rectifier and a bypass input for the ST/SW.

3.9.4.6 Q: WHAT SHOULD BE THE CONNECTION WIRE SIZE IN MM2?

A. The wires should fit he current they stand for. Each P+ module consumes 15A of current maximum on
the input of each phase. This current has to be multiplied by the total number of modules. Each country
can have different accepted standards for wire size assignment. The size of the neutral wire should
stand for 1.5 times the maximum current of the phase wires, because the rectifier in each phase works
with the neutral independently. When connecting a unit with two input cables, the neutral wire is double
size anyway because the input and the bypass of Power Plus have single common neutral connection.

3.9.4.7 Q: IS THERE A NEUTRAL CONNECTION ON THE INPUT AND THE OUTPUT OF THE

UNIT

?

A. Power Plus units operate with neutral on input and on the output. To achieve three-phase operation
without neutral delta to star (or the opposite for output) transformers can be used.

3.9.4.8 Q. WHAT IS THE TERMINALS TYPE OF THE UNIT FOR THE INSTALLATION?

A. The terminals are 70mm screw type on all models. To connect you will need to use cable ends with
your cables with 8mm or 10mm hole.

3.9.4.9 Q. DOES THE UNIT HAVE DRY CONTACT FOR THE “LOAD ON BYPASS”

SIGNAL

A. Yes, it is located on the ST/SW module. Unscrew two mounting screws on the front panel of the
ST/SW module and slightly pull it out. The dry contact connection is on its top, 230v rated, usually for use
with electricity switchboards with make-before-break load transfer function for protection.

?

3.9.5 MECHANICS

3.9.5.1 Q: THERE ARE 50/40KVA AND 100/80KVA ST/SW MODULES. WHY?

A. There are two types of ST/SW modules, for 50/40KVA and for 100/80KVA. For example, for a 30k unit
you should think if after all additional upgrades (an additional module each time) more then 50KVA load
will be reached. If so, then it’s better to order a unit with ST/SW module for 100Kva. Of course, there is a
price difference. Don’t forget that the base module for these units can also be 50/40Kva or 100/80Kva.
So, every customer might require different solution.

3.9.5.2 Q: HOW CAN THE UNIT BE UPGRADED IF THERE ARE NO FREE SHELVES?

A. In these systems the housing is modular. In order to upgrade the system with a new module an
additional shelf should be installed. This is a simple process, which might take no mode then half an hour
for single person.

3.9.6 COMMON PROBLEMS

3.9.6.1 Q: AN ALARM LED IS IN RED ON THE FRONT PANEL. HOW CAN I QUICKLY

UNDERSTAND WHAT IS WRONG

A. On the left side of the controller there is an “alarm off” button. When you press it, you will see the list
of all the alarms for the system and their state. They can be browsed using the up and down arrows. The
active alarms will have an asterisk (*) sign near them.

Power+ Technical Guide 43

?

Gamatronic Electronic Industries Ltd.

3.9.6.2 Q: WHEN I LOOK AT THE LIST OF THE ALARMS, I CAN SEE SOME ALARMS WHICH

ARE ALWAYS ON

A. There is a number of alarms that might be on. One of them is the “STRTUP” alarm, which stands for
the “startup time stamp”. This alarm only means that the unit is on, and it will not raise an “alarm signal”.
Other alarms can be the “user alarm 1-4”, which are the input dry contacts. If they are not in use, you
can disable them through the controller menus.

. WHY IS THAT?

3.9.6.3 Q: WHAT WILL HAPPEN IF THE EQUALIZING MODE WAS ACTIVATED IN THE UNIT?

A. The equalizing mode should always be set to DISABLED, this feature is not available. If you had it on
in your system, please note that it could simulate a failure condition and a shutdown to the computers.
On all the units today this feature is absent. Please contact your Gamatronic representative to upgrade
your controller software version.

3.9.6.4 Q: THE UNIT ALWAYS SHOWS BATTERY TEST FAULT ALARM. THE BATTERIES

ARE

OK. WHAT IS WRONG?

A. On some older systems the controller might show false battery alarms. This was corrected, so in case
that you have this problem and positively sure that the batteries are alright, please contact your
Gamatronic representative to upgrade your controller software version. After you perform this action, the
unit will still show battery test fault. Please perform manual battery test to restore normal operation.

44 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

4. SYSTEM INSTALLATION

RISK OF ELECTRICAL SHOCK OR INJURY!
INSTALLATION MAY BE PERFORMED BY

WARNING

Figure 4-1 illustrates the cabling of the POWER+ system to the mains electricity cabinet.

QUALIFIED TECHNICIAN ONLY!

Figure 4-1: POWER+ system connections

Power+ Technical Guide 45

Gamatronic Electronic Industries Ltd.

Figure 4-2 below shows required switch and wire ratings for 10-100kVA installation.
For battery connections, see

Figure 4-2: Switch and wire ratings for 10-100kVA installation

Figure 6-3 on page 68.

POWER+ 400 V MODEL

UPS OUTPUT

CAPACITY (KVA)

10 16 2.5 32
20 32 6 63
30 50 10 100
40 63 16 120
50 80 25 140
60 100 35 175
70 100 35 200
80 125 50 225
90 140 50 250

100 160 50 300

S2 – S6

AND RA101

(AMPS)

WIRES
(mm2)

RA101

(OPTION)

(AMPS)

46 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

4.1 INSPECTIONS TO BE PERFORMED PRIOR TO

INSTALLATION

Type of check Requirement

Ambient temperature in the immediate

1.
location of the equipment

2. Humidity and condensation

3. Ventilation

4.

Foundation and route to installation site

When planning the location of the UPS

5.

units, room for access to battery
cabinets and electrical boards is critical.

Circuit breakers on the electrical board

6.

supplying the system
Diameter of input and output power

cable connections, PE (Gnd) and neutral

7.
lines.

Recommended: between 15°C and 25°C
Required: between 0°C and 40°C

Verify that there is no water condensation or
dampness within the installation site

Verify that sufficient airflow or forced ventilation is
provided for battery cabinets location

Verification of adequate structure, space and
clearance for dimensions and weights of the UPS
units and their battery cabinets

Verify 40 cm clearance at rear for cable connections
and 100cm at front for user access and service

Must be in accordance with Gamatronic system
specifications and connection schematic

Must comply with local and international codes, and
be appropriate for the circuit breakers protecting
them. Refer to connections schematic.

Value,
Verification

Lightning / Voltage surge protection on

8.

electrical board supplying the system.

Voltage surge suppressors type B must be installed
between each phase and the neutral line:

Ratings: 300VAC for 220-230VAC mains.

Phase-to-Phase: 380*VAC, +10%, -15%

9. AC input voltage

Phase-to-Neutral: 220*VAC, +10%, -15%

10. Voltage between neutral and ground 0 – 2 VAC

Must be performed only by authorized personnel in

11. System installation and start-up

accordance with connection schematic, Gamatronic
system specifications and this User Guide

* Or other, according to nominal voltage rating of local power mains.

R-S
S-T
T-R

R
S
T

Power+ Technical Guide 47

Gamatronic Electronic Industries Ltd.

4.2 INSTALLATION PROCEDURE AND SYSTEM START-UP

Operation

Remove rear covers and connect AC input and output power cables to terminals according to markings as shown
in this User Guide and according to connection schematic.

1.

Verify correct phase sequence
Connect ground lines to busses according to markings as shown in the connection schematics (Figure 3-2 on

2.

16, Figure 3-3 on page 17, Figure 4-1 on page 45). Verify secure connections.

page
Connect the DC power cables of the battery cabinets to the UPS terminals according to markings as shown in

Figure 4-1 on page 45 and Figure 6-3 on page 68. Connect neutral and ground lines to busses as above.
Verify correct polarity of the connections (+ / N / -)

3.

terminals. Auxiliary contacts of Battery C.B.s are connected to UPS Controller inputs “Bat CB” and “Com” as
marked, and as shown in

An external dual-pole / N.C. EPO switch may be connected according to connection schematic.

4.

EPO wiring and switch rating must be rated for at least 5A / 230VAC.
Before connecting power to each system verify again that all connections are secure and are according to

5.

instructions and schematics.

between board and UPS

Between the Battery Cabinets C.B.s / Terminals and the UPS

Figure 7-2 on page 70.

Follow the instructions in section 4.3, “Initial Start-up Sequence”, on page 49.

6.

48 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

4.3 INITIAL START-UP SEQUENCE

Note: Before first setting up the UPS, make sure that the load is not connected.

1. Ensure that the maintenance bypass switch (if installed) is disconnected.

2. Turn the AC input and AC bypass switch ON and wait (for about 2 minutes) for the

POWER

+

to initialize.

When applying power to the POWER

+

, the system automatically runs the startup process

without a need to press the On/Off button.

The start-up sequence will begin and the control panel will show the following sequence.
(The details will vary, depending on your application.)

During this step, the LEDs are also checked sequentially.

Power up

Start-up 1

Figure 4-3: Start-up screen 1

Power up

Start-up 2

Figure 4-4: Start-up screen 2

Power up

Start-up 3

Figure 4-5: Start-up screen 3

Power up

Start-up 4

Figure 4-6: Start-up screen 4

Power+ Technical Guide 49

Gamatronic Electronic Industries Ltd.

3. Ensure that you have a normal reading on the System Controller display. The bar graph
on the left side displays loads of all 3 phases as shown in

Figure 4-7.

Power up

Default
window

Figure 4-7: Normal display of the controller LCD (default)

4. Switch all battery switches ON on all battery cabinets.

Checks to be performed following initial startup

Type of check Requirement

Phase to Phase:

AC input voltage during operation under load.

1.

Take measurements on the input terminals of
the system

Not less than 2% below no-load values measured in item 5 below.
Phase to Neutral:

Not less than 2% below no-load values measured in item 5 below.

With no load on the system, measure current

2.

circulation between the units.
With no load on the system, measure the DC

3.

voltage of the system.

Irst should be <15 A

Total DC voltage between + and – terminals should be
between 850 V and 880 V.

Voltage between neutral and ground during
operation under load

4.
On the input terminals of the system

5. System output voltage

6. Total system load / output current

7. Correct and orderly operation

0–2 VAC

220 V +/- 2 %
or other according to system specifications

Verify that the system is not overloaded in relation to system
specifications

Verify that the UPS is operating normally in accordance with this
User Guide and that no alarms or fault indications are evident

NOTE: It is the responsibility of the customer to notify Gamatronic Electronic Industries Ltd. and receive
approval for any deviations from these requirements.

50 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

4.4 CHECKS TO BE PERFORMED FOLLOWING INITIAL

STARTUP

Type of check Requirement Result

Phase to Phase:
Not less than 2% below no-load values measured in

AC input voltage during operation under load.

8.

Take measurements on the input terminals of
the system

item 5 below.

R­S

S­T

T­R

With no load on the system, measure current

9.

circulation between the units.
With no load on the system, measure the DC

10.

voltage of the system.
Voltage between neutral and ground during

operation under load

11.
On the input terminals of the system

12. System output voltage

13. Total system load / output current

Correct and orderly operation

14.

Phase to Neutral:
Not less than 2% below no-load values measured in

item 5 below.

Irst should be <15A

Total DC voltage between + and – terminals
should be between 850V and 880V.

0–2VAC

220V +/- 2%
or other according to system specifications

Verify that the system is not overloaded in relation to
system specifications

Verify that the UPS is operating normally in accordance
with this User Guide and that no alarms or fault
indications are evident

R
S
T

R
S
T

NOTE: It is the responsibility of the customer to notify Gamatronic Electronic Industries Ltd. and receive
approval for any deviations from these requirements.

Power+ Technical Guide 51

Gamatronic Electronic Industries Ltd.

4.5 SPECIAL CONSIDERATIONS FOR 1-PHASE OUTPUT

This section discusses some special considerations for Power+ UPS System single-phase
output (3/1 and 1/1 configuration).

4.5.1 DIP-SWITCH SETTINGS ON THE MODULES

1. On the left side of each module, close to the front panel is a small window with access to

three dip-switches.

2. For standard three-phase input and output (3/3 configuration) dip-switch no. 3 is set to

ON(LEFT) position.

3. For single-phase output (3/1 or 1/1 configuration) set the dip-switch no. 3 to OFF(RIGHT)

position on all of the modules of the System.

4.5.2 WIRING OF INPUT AND OUTPUT TERMINALS

1. For 3/1 configuration (Three phase input and single-phase output) the Bypass AC input

terminals R,S&T must be shorted between them with 35mm² wiring and so must be the
AC output terminals R,S&T.

2. For 1/1 configuration (Single-phase input & output) The UPS (Rectifier) AC input

terminals R, S & T must also be shorted between them.

3. Illustrations of 3/3 3/1 and 1/1 External wiring configurations are presented in attached

files.

52 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

4.5.3 SYSTEM START-UP

After start-up of the system the POWER+ controller automatically displays the Phase readings
according to the System configuration.

Table 4-1: Power Configuration DIP Switch Settings

Switch Purpose Set left (on) Set right (off)

SW1 Master module

preference

SW2 Output power

Preferred master
select(not used)

60 Hz 50Hz

frequency selection

SW3 Output power phase

3-phase Single-phase

selection

Automatic via
console

Figure

Power+ Technical Guide 53

4-8: Example of dip switch setting for 3/3 phase, 50 Hz UPS

Gamatronic Electronic Industries Ltd.

4.6 DIP SWITCH SETTINGS OF THE UPS MODULES

y Dip switch #1(in bottom) should always be OFF(RIGHT), designed for manual master

operation in stand-alone mode.

y Dip switch #2(in middle) should be ON(LEFT) for 60Hz and OFF(RIGHT) for 50Hz

inverter operation.

y Dip switch #3(in top) should be ON(LEFT) for 3 phase and OFF(RIGHT) for 1 phase

inverter output.

NOTE: All settings must be identical on each of the modules in a single (non-parallel) system.

The location of the dip switches on a UPS module is shown in the picture below.

54 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

5. USING THE SYSTEM CONTROLLER

From the default system screen (the “Main Screen”), pressing the "ENTER" button displays the
main menu.

Figure 5-1: The controller’s main menu

Table

5-1: Controller main menu options

SYSTEM
UPS
SELFTEST
HISTORY
BATTERY
ALARM
SETUP
STATIC SW
COMM

General information such as voltages, currents etc.

Information for a specific UPS module

Self checking of the Controller's components (supply, RTC, memory)

History log events (last 255 events, dated and timed)

Charging / discharging voltages and currents, battery test etc.

Detailed alarm status

Configuring the system (number of modules, alarm, time etc.)

Static Switch data

Determining the type of communication (TCP/IP, RS232 or WING)

Power+ Technical Guide 55

Gamatronic Electronic Industries Ltd.

5.1 SYSTEM INFORMATION DISPLAY

Figure

5-2: Main menu option 1 ("System")

The SYSTEM option on the Main Menu (option 1) shows the DC voltages and current (positive,
negative and summary):

Figure 5-3: System DC voltages

56 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

1.

From the DC voltages screen, press the ► key to view the current output power
factors

2

.

Figure 5-4: Output power factor 1

Press ► again to view the current input power factor.

2.

Figure 5-5: Input power factor 1

From the DC voltages screen, scroll down to view the three-phase input and output

3.

total voltage and current:

Figure 5-6: Overall phase voltages/currents

Scroll down again to see accumulated operation time and duration of current

4.

session.

Figure 5-7. General timers and counters

2

1 kVA is 1000 VA. Apparent power is measured in VA which is a reactive (i.e. a mix of both capacitive
and inductive) load’s RMS voltage multiplied by the RMS current. True power is VA multiplied by the
power factor, and the power factor is the cosine of the phase angle between voltage and current. A
reactive load that draws an apparent power of 1000 VA and has a 0.5 power factor is consuming 500
watts of power. If a device were purely inductive, it would have a power factor 0. See also footnote 1, on
page 4.

Power+ Technical Guide 57

Gamatronic Electronic Industries Ltd.

5.

Press the down arrow again to see the jumper settings on PC714.

Figure 5-8. Jumper setting and general information

See section 3.7.1 beginning on page 33 for more information about jumpers 1, 2, 3, 6, and 9 on

PC714.
See Section

6. Pressing the down arrow once again displays measurements of various internal

6.2.1.2 on page 69 for instruction for setting the battery capacity.

voltages of the controller.

Figure 5-9. Internal controller voltages

7.

Press "ENTER" again to return to the menu (Figure 5-1).

58 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

5.2 DISPLAY UPS MODULE DATA

1. From the Main Menu, select option 2 “UPS MODULE”. The message shown in

Figure 5-11) appears.

2. Use the ▼ and ▲ keys to scroll between UPS modules. The display shows the

voltage and current measurements for each module (see

3. Scroll ► and ◄ keys to view additional information for the specific module chosen

(see

Figure 5-13 on page 60).

Figure 5-12 on page 60).

Figure 5-10: Main Menu option 2 (“UPS Module”)

Power+ Technical Guide 59

Gamatronic Electronic Industries Ltd.

Figure 5-11: LCD Panel – Selection

Figure 5-12 and Figure 5-13 show parameters for the first module of a UPS system with four

modules. (UPS: #01/04).

Figure 5-12: Module phase voltages/currents

Figure 5-13: Battery voltages, I-active current

60 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

5.3 SETTING THE NUMBER OF UPS MODULES

(The default system password is 8 left arrows [8x”<”]. To change the password, see 11.2,
“

Setting Password Level 1” on page 86.

From the Main Screen, press Ent to display the Main Menu

1.

2. Select "7>SETUP" (Figure 5-1).

3. Enter the password and press Ent (default password is 8 x “<”).

4. Select "8>Service" (Figure 5-14).

5. Select "5>Configure" (Figure 5-15).

6. Select "2> # of UPSs" (Figure 5-16).

7. Set the number of UPS modules by using the ► and ◄ keys (Figure 5-17).

8. Press Enter to complete the setup.

The controller applies and saves the new number of modules.

Figure 5-14: Controller menu #2

Figure 5-15: Controller menu #3

Figure 5-16: Controller menu #4

Figure 5-17: Number of UPS modules

Power+ Technical Guide 61

Gamatronic Electronic Industries Ltd.

5.4 RETRIEVING HISTORY (LOG OF EVENTS)

1. Select "4> HISTORY" (Figure 5-1). The last 255 events reserved in the LOG are

displayed, as shown in

2. Navigate the LOG by scrolling using the "up" and "down" arrow keys( ).

Figure 5-18.

Figure 5-18: Log display

Log messages are formatted as described in Table 5-2 below.

Table 5-2: Format of log messages

FIELD DESCRIPTION
Time
Date

HH:MM:SS – time message logged.

YY:MM:DD – date message logged.

Dc voltage between "+" and "-" terminals for all events except LOADBP.

Data

For LOADBP, the field holds the STSW status. See

Table 5-4 below for

interpretation of STSW status codes.

IN or OUT
Description
Event number

"IN" = start of event or condition; "OUT" = end of event or condition.

See

Table 5-3 below.

0 through 255, 255 being the most recent.

Example of a log message:

11:23:56 09.01.28 865 IN -> E.P.O. 254

This message means that at 11:23:56 on January 28

th

2009, Emergency Power Off alarm was

registered as event 254; dc voltage at the time was 865 V being a sum of (V+ -N) and (V- -N).

Table 5-3 below lists the various "description" field values that can appear in a log message.

62 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Table 5-3

: Log Messages "description" field

Alarm

01 UPSMAJ More than 1 UPS Module is sending an alarm or fault warning.

02 UPSMIN Single UPS Module is sending an alarm or fault warning.

03 ------ N.A.

04 ------ N.A.

05 LOADBP

06 VIBRA_

07 OVTEMP Excess temperature.

08 OUTFLT No ac output to load.

09 BAT-HI Excessive battery voltage.

10 ------ N.A.

11 BATEND End of battery backup. Battery is discharged to shutdown limit.

12 BATLOW Low battery voltage.

13 STSWRN Static Switch Warning or alarm.

14 E.P.O. Emergency Power Off is active.

15 EQ-HST

16 BATFLT Batteries failed last test.

17 USER-1 User 1 input open.

18 USER-2 User 2 input open

19 USER-3 User 3 input open.

20 AC-BRN Input ac supply brown-out.

21 ACIN_H Ac input excessive.

22 ACFAIL Ac input failure.

23 STSWCM Static Switch does not respond.

24 SLFFLT Last controller self-test failed.

25 BAT-CB Battery circuit breaker open.

26 CURSHR

27 UPSOUT Fault (no current) in 1 or more output stage.

28 UPSHDN UPS shutdown by EPO, Battery Discharge, ON/OFF pressed.

29 OVLOAD Load current is high.

30 UPS-CM

31 STRTUP Startup time-stamp.

32 ------ N.A.

Message Explanation

#

Load is now running on bypass. "Data" field holds the STSW transfer
code – see Table 5-4 for interpretation of the STSW transfer code.

Alarm(s) vibrating. Alarm is frequently raised and lowered. Ignore to avoid
loading the log filling up.

Battery is currently charging in equalizing mode, dc voltage is temporarily
increased.

Current Sharing fault, load current is not equally divided between
modules.

One or more UPS’s not responding.

Power+ Technical Guide 63

Gamatronic Electronic Industries Ltd.

5-4: Static Switch transfer code (for LOADBP event)

Table

The STSW transfer code, given as a decimal, is the sum of the eight components listed in this table.
Each component has its own weight if detected, and a weight of zero if not detected.

COMPONENT

WEIGHT

1
2
4

8
16
32
64

128

Example: If LOADBP data = 67 = (64+2+1), this means that three conditions were present:

y (64) Instruction to transfer the load was issued by the controller.

y (2) Low peak voltage detected.

CONDITION DESCRIPTION

Inverter voltage blackout for >3 ms.

Inverter peak voltage <185 V (brownout).

Inverter peak voltage high <185 V (brownout).

Frequency beyond limits (45-65 Hz).

Inverter average voltage low.

Inverter average voltage high.

Instruction for load transfer was received from the controller.

Instruction for load transfer was received from the Static Switch.

y (1) Voltage blackout encountered.

64 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

5.5 SYSTEM CONTROLLER ALARMS

System Controller alarms are described in Table 5-5.

Table 5-5: System controller alarms

AC-BRN Input AC supply Brown Out

ACFAIL AC input failure

ACIN_H AC input excessive

BAT-CB Battery Circuit Breaker Open

BATEND End of battery backup. Battery is discharged to shutdown limit

BATFLT Batteries failed last test

BAT-HI Excessive battery voltage

BATLOW Low battery voltage

CURSHR Current Sharing fault, load current is not equally divided between modules

E.P.O. Emergency Power Off is active

EQ-HST

LOADBP Load is now running on bypass

OUTFLT No AC output to load

OVLOAD Load current is high

OVTEMP Excess temperature

SLFFLT Last controller self-test failed

STRTUP Startup time-stamp

STSWCM Static Switch does not respond

STSWRN Static Switch Warning or alarm

UPS-CM

UPSHDN UPS shutdown by EPO, Battery Discharge, ON/OFF pressed

UPSMAJ More than 1 UPS Module is sending an alarm or fault warning

UPSMIN Single UPS Module is sending an alarm or fault warning

UPSOUT Fault (no current) in 1 or more output stage

USER-1 User 1 input open

USER-2 User 2 input open

Battery is currently charging in equalizing mode, dc voltage is temporarily
increased

One or more UPS’s not responding

USER-3 User 3 input open

VIBRA_

Power+ Technical Guide 65

Alarm(s) vibrating. Alarm is frequently raised and lowered. Ignore to avoid
loading the log filling up.

Gamatronic Electronic Industries Ltd.

6. BATTERIES

6.1 BATTERIES AND CONFIGURATIONS

The POWER+ is flexible in structure, in that it may be extended by adding modules as required.
The battery bank is common to all modules and may comprise one or more branches to include
a redundant battery if desired.

For systems from 10kVA through 30kVA, the batteries may be internal; otherwise, the batteries
are housed in external cabinets. See
and connections.

6.1.1 INTERNAL BATTERIES

Up to 3 internal packs, each containing 64 × 12v/5Ah batteries, may be housed in the Power+
system cabinet. This would provide 4 minutes of backup time at full load, on a redundant
system of 5 modules (total 40kVA). See

Each battery pack is 6U high and weighs about 135 kg on average, depending on the
manufacturer and model. It comprises 4 drawers, each containing 16 batteries, to facilitate
removal and replacement. See

Figure 6-3 on page 68 for details on battery cabinet wiring

Figure 6-1 below.

Figure 6-2 on page 67.

System controller

4 x 10kVA UPS modules
(plus 1 x redundant)

DC distribution

Static switch

Battery drawers

Figure 6-1: 40kVA N+1 System with Internal Batteries

66 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Figure 6-2: Internal Battery Drawer – Exploded View

6.1.2 EXTERNAL BATTERIES

External batteries are housed in separate cabinets.

These batteries are connected to the system by heavy duty cables, care must be taken to
ensure correct polarity. Overall voltage may be as high as 870vDC + to -, i.e. +435vDC and –
435vDC with respect to ground/earth. Precautionary measures must be taken whenever
connecting the battery or servicing the battery cabinets.

6.2 INSTALLING AND CONNECTING THE BATTERIES

As shown in the diagram, the DC output cable from the batteries is connected directly to the small
Anderson connectors on the UPS rear panel.

WARNING: When connecting the batteries to the UPS:

y The UPS’s AC INPUT circuit breaker must be in the OFF position,
AND

y The battery circuit breaker must be in the OFF position.

WARNING: After connecting the batteries to the UPS, do not turn on the battery circuit breaker until the
UPS’s AC INPUT circuit breaker is turned on.

Cables from battery banks are connected to the Anderson connectors on the DC distribution
shelf as indicated in

Power+ Technical Guide 67

Figure 3-11 on page 27 and Figure 3-12 on page 27.

Gamatronic Electronic Industries Ltd.

Figure 6-3: Connection diagram for external battery

68 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

6.2.1 CONFIGURING THE BATTERIES TO THE SYSTEM

When you are installing the battery for the first time, or if you have changed either

y the number of battery sets (1 battery set = 64 batteries)

OR

y the total Ampere/hour capacity of your batteries,

you must reconfigure the batteries to the system.

6.2.1.1 TO (RE)CONFIGURE THE NUMBER OF BATTERY SETS:

1. On the system control panel, press Ent.

2. Choose Setup, press Ent.

3. Enter the system password (the default password is eight left arrows),
press Ent.

4. Select Service, press Ent.

5. Select Configure, press Ent.

6. Select # of Batteries, press Ent.

7. Use the up and down arrow keys to modify the number of batteries,
then press Ent.

6.2.1.2 TO (RE)CONFIGURE THE BATTERIES' AMPERE/HOUR RATING:

1. On the system control panel, press Ent.

2. Choose Setup, press Ent.

3. Enter the system password (the default password is eight left arrows),
press Ent.

4. Select Battery, press Ent.

5. Select Capacity, press Ent.

6. Choose the battery set that you want to configure and press Ent.

7. Use the arrow keys to set the desired number of Ampere/hours,
then press Ent.

Power+ Technical Guide 69

Gamatronic Electronic Industries Ltd.

7. DRY CONT ACTS AND ALARM TERMINALS

Dry Contact terminals are located on the right side of the rear of the POWER+ controller

module, as shown in

Figure 7-1: Location of dry contacts at rear of POWER+ controller module

Figure 7-1, labeled A and B.

Figure 7-2: Dry Contacts “group A” (as per

“INPUTS” DRY CONTACT DESCRIPTION

Figure 7-1)

NAME IN

ALARM DISPLAY

COM Shared contact ---

BAT CB

Auxiliary contact (N.C.) for battery Circuit
Breaker trip indication

BAT CB

N.C.1 USER1 – user assigned dry contact USER-1

N.C.2 USER2 – user assigned dry contact USER-2

70 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

7.1 DC CURRENT MEASUREMENT

The dry contacts in Figure 7-2 labeled “DC CURRENT MEASUREMENT” are for monitoring

battery current. Each group may be connected to a different current sensor. Measurements can
be taken from up to three battery sets, as per the three groups of Current Measurement
contacts.

7.2 TEMPERATURE SENSOR

An optional temperature sensor (see Figure 7-3) may be attached to the contacts labeled

TEMP to monitor the temperature of the batteries.

Figure 7-3: Dry Contacts “group B” (as per Figure 7-1)

To install the temperature sensor, connect the sensor according to Figure 7-3 and Figure 7-1.

To see the temperature reading, a configuration change must be made to the controller. Enter
the following commands on the system controller panel:

Ent, Setup, Password (default password is 8 left-arrows),
Battery, Enable/Disable Options, Enable Batt Temp Sensor

To see the temperature reading, enter the following commands on the system controller panel:

Ent, System, 5 x down arrow. Press Esc to exit.

7.3 USER-DEFINED ALARMS

There are four groups of 3 contacts each (see Figure 7-3) that can be used for user-defined

alarms. In each group, either the N.C. or N.O. contact is used together with the COM contact.

Power+ Technical Guide 71

Gamatronic Electronic Industries Ltd.

8. PERIODIC MAINTENANCE

The Power+ system should undergo periodic maintenance at least once a year.

8.1 OBJECTIVES OF THE PERIODIC MAINTENANCE

The periodic maintenance is performed to verify the following:

y Power+ UPS and batteries are in proper electrical and physical condition

y The operation of the UPS and its batteries conform to design specifications

y The UPS and batteries are in compliance with all relevant safety standards and

regulations

8.2 RECOMMENDED TOOLS

Before proceeding with the periodic maintenance make sure that the following tools are
available to you:

• Philips screw driver

• Flat head screw driver

• Thermometer

• Oscilloscope

• Air compressor (for cleaning)

• Flashlight

72 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

8.3 MAINTENANCE PROCEDURES AND REPORT

Record the values of all parameters checked and of measurements taken during the periodic
maintenance in the form below. Fax the completed form to Gamatronic at [phone].

Power+ model and configuration
Company ______________________
_______________________________
Site ___________________________ Phone ________________ E-mail _________________
Power+ Model __________________
[ ] Up to 50 kVA [ ] Up to 100 kVA

Type of maintenance: [ ] Annual [ ] Semi-annual [ ] Quarterly
System S/N (found at the bottom left side of the base): ______________________________________
Static Switch S/N (found on top of Static Switch after opening):______________________________
Module S/Ns (found on the right side of each module after removing from housing – six last digits only):

1________________ 2________________ 3________________ 4_____________ 5_______________

6________________ 7________________ 8________________ 9_____________ 10______________

Technician Name _______________

_______________________________

Address _______________________________________
_______________________________________________

No. of modules _______
[ ] 2-phase [ ] 3-phase

Date
___________________

No. of redundant

modules _______

Signature
___________________________

Visual Inspection
OK [ ] Not OK [ ]
Environmental Inspection

Environmental temperature

Ventilation

Air conditioning

Comments _________________________________________________________________________________

Display Panels

LCD Display

LEDs

Voltages

Verify that displayed dc voltages, rectifier input voltages, and inverter output voltages are showing proper values. Verify the readings

for the UPS as a whole (menu option 1, System) and for each module (menu option 2, UPS Module).

Dc voltages

Rectifier input voltages

Inverter output voltages

Serial Number / Clock and Calendar

 Done

 Done

Comments ________________________________________________________

________°F

[ ] OK [ ] Not OK
[ ] Yes [ ] No

[ ] OK [ ] Not OK Comments ____________________________
[ ] OK [ ] Not OK Comments ____________________________

(+)_______________ (-)_______________ (Total)_______________
Volts: __________ __________ __________
Amperes: __________ __________ __________
Hertz: __________
Volts: __________ __________ __________
Amperes: __________ __________ __________
Hertz: __________

Verify that the Power+ serial number is registered in the System Controller memory. If not, enter the
serial number into the memory and save.

Verify that the Power+ clock and calendar show the right time and date. If either time or date are
incorrect, enter the correct information and save.

Power+ Technical Guide 73

Gamatronic Electronic Industries Ltd.

Alarms

Use menu option 6 to display the alarms. Active alarms are identified by an asterisk to the right of the alarm name. List the names of
any active alarms: ___________________ ___________________ ___________________

 Done

I-active / I-bus

Verify that the difference between I-active and I-bus for each module is no greater than 1 mA.

[ ] OK [ ] Not OK Comments ____________________________________________________
Bypass Test and Module Maintenance

Connect an oscilloscope to Power+ output terminals L1 and N. Press the INV/BYPASS button twice to transfer the UPS to bypass
mode. Verify that the transfer takes place normally, with no interruption of power to the load.

[ ] OK [ ] Not OK Comments ____________________________________________________

 Done

 Done

Software Version

Check the software version in the System Controller. If it is not the latest, replace the EPROM with the latest version.

 Done

Check Front and Rear Fans

Use a flashlight to visually verify that the 4 front fans and 2 rear fans in each module are operating.

Front fans

Rear fans

Voltage Measurements

Measured value: ____ Vac Measure the voltage between Neutral and Ground at the bypass input. The value should be no

Use a voltmeter to measure the bypass input voltages according to the table below. Compare your measurements with the console
display of the bypass input voltage.

Location Phases

Calibration

Select option 7 from the Main Menu.
When prompted for the password press the left arrow key 8 times and press Enter.
When the submenu appears, select option 2, Module Configuration, then option 7, Dc calibration or option 8, Ac calibration. Enter
here any calibration performed: __________________________________________________

Verify that the Power+ clock and calendar show the right time and date. If either time or date are
incorrect, enter the correct information and save.

Remove each module and clean the exterior and rear contacts with compressed air. Check the rear
of each module for corrosion.
Blow compressed air into the module front to back and back to front.

Return the modules and transfer the UPS back to Inverter mode. Verify that the UPS functions
normally.

Comments ____________________________________________________

[ ] OK [ ] Not OK Comments ____________________________
[ ] OK [ ] Not OK Comments ____________________________

greater than 5 Vac..

Voltmeter
reading

L1 – N

L2 – N Inverter output

L3 – N

Console
reading

YES NO

Readings match?

74 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

Battery Checks

Turn the battery circuit breaker to Off and disconnect all Anderson connectors in the battery set.
Record the battery serial number, type, and number of cells in the table below:

Battery

manufacturer

Battery model Rating (Ah) Number of strings (x 32)

Use a power resistor of 0.5

Ω (300 W rating recommended) for the load to check the voltage drop across the

terminals of each battery. There should be no more than a 10 Vdc drop for any battery.
Replace any batteries that seem to be inadequate.

BATTERY STRING #1 BATTERY STRING #2

Batt.

no.

1 17 33 49

2 18 34 50

3 19 35 51

4 20 36 52

5 21 37 53

6 22 38 54

7 23 39 55

8 24 40 56

9 25 41 57

10 26 42 58

11 27 43 59

12 28 44 60

13 29 45 61

14 30 46 62

15 31 47 63

16 32 48 64

Good Bad

Batt.

no.

Good Bad

Batt.

no.

Good Bad

Batt.

no.

Good Bad

END OF MAINTENANCE PROCEDURES REPORT

Power+ Technical Guide 75

Gamatronic Electronic Industries Ltd.

9. TROUBLESHOOTING

The system log (option "4 – HISTORY" on the main menu) can be very useful in determining the cause
of a UPS malfunction. See section

The indicator lights on the UPS module's front panel can also signal a malfunction.

5.4 "Retrieving History (LOG of Events)" on page 62.

Figure 9-1: UPS module front panel

As shown in Figure 9-1 there are three LEDs on the front panel of each UPS module: Alarm,

Output and Line. The internal buzzer in the UPS module sounds when there is no
communication with the system controller.

These 3 LEDs and the buzzer indicate the status of the UPS module (see

The alarm LED is red, line and output LEDs are green.
Normal condition is indicated by the green line LED and output LED on, with no beeps from the
buzzer.

Table 9-1 below).

76 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

9-1: UPS Module Indicators

Table

CONDITION LINE

Wake-up
Start
Normal

Operation
Abnormal

Input voltage
One phase

abnormal input

High Input
Current

Vdc > 450V
Vdc > 500V
DC imbalance
Low Vdc< 360V
Vdc very low,

< 320V
DC critical fail

< 200V
Circulation

Current
Output overload

Output is
disconnected

Communication
failed

Output
short-circuit

(GREEN)

On On On ♫

Off Off Off About 1 minute

On On Off

Off On On ♫

Blinks On Off ♫

Blinks On On ♫

On Off Off ♫ High Vdc

On Off On ♫ Very high Vdc

On On Blinks ♫

On* On Blinks

On* Off On

Blinks Off On

On Off On

On Blinks Off

On Blinks On Result of output

On On On ♫ Or absence of

Blinks Off On ♫

OUTPUT
(GREEN)

ALARM
(RED)

BEEPS REMARKS

* Mostly will be
caused by Vin
fault that will turn

off LINE LED

overload

System
Controller

Power+ Technical Guide 77

Gamatronic Electronic Industries Ltd.

Table

9-2: Troubleshooting table

1

After the startup the unit won’t
switch to inverter.

2 On a module OUTPUT and

ALARM LEDs are flickering.

3 The unit shows output load while

there is no load connected.

PROBLEM SOLUTION

1. Check the phase sequence of the bypass
input. Swap phases S (L2) and T (L3) on this
input for proper phase rotation.

2. Make sure that the bypass input voltage and
frequency is within the tolerance.

1. Try resetting the module by pushing the
RESET button on its front.

2. Check its output voltage through the controller.
If no voltage – replace the module.

1. Check and compare each module’s output
voltage on each phase. One of the modules
might be configured to a voltage different from
others, thus causing circulation currents on the
output.

2. Compare I-BUS and I-ACT for each module in
the “UPS module” menu on the controller. If
these values are not similar for one of the
modules, check it individually.

4 Contactor sounds can be heard

from the unit from time to time,
but no transfers to bypass have
been registered.

5 Red alarm LED is lit on the

controller.

6 LINE LED blinks in green on a

module, while output is green and
alarm is not lit.

These units have internal synchronization
contactor, which should protect from switching to
bypass and feedbacks while the bypass input is not
synchronized with inverter. It will switch off
automatically each time bypass frequency gets out
of tolerance, and when the problem is restored it
will switch back on. Check the supply. Power+
unit’s frequency window is adjustable from ±0.5Hz
to ±4Hz.

1. To see the list of active alarms with short
descriptions, press the ALARM OFF button
(the middle one on the right hand side of the
controller). Navigate with arrow keys.

2. To see the list of active alarms with full
description, press and hold “ESC” key to get in
to the menu and choose “Alarms Status”.
Navigate with arrow keys.

A phase is missing on the main input. If the problem
exists on one module only, check the input fuses
(located on the rear side of base unit, above the AC
terminals). There is one fuse for each phase of
each module.

78 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

7 DC voltage gets low, sometimes

until the unit switches off and
goes on bypass.

1. The unit might be in the middle of the battery
test. Check it through the controller. If it is,
either let it finish or stop it manually.

2. Check the current limit and battery temperature
compensation settings in the controller. They
can cause severe drop in DC voltage if not
configured properly.

3. Try to remove the system controller and check
if the DC voltage restores to normal. If it does,
check controller settings. This will not stop P+
operation or cause interference with the load.

4. If battery temperature compensation and/or
battery current limit are enabled, make sure
that the unit has the required optional sensors
installed. If not, disable the corresponding
feature.

8 The modules are working

normally, but the system
controller is off.

9 The system is running normally,

but shows UPS-CM alarm.

10 No values are received from the

unit through the communication
port or through the WING.

1. Check AC fuses (located on the rear side of
base unit, above the AC terminals) and DC
fuses (located behind a blank cover above the
ST/SW module).

2. Replace PC093 power supply PCB inside the
system controller.

3. Replace the system controller.

Check the number of modules value in the
controller. If the system is set up for more modules
then actually exist, it will fail to communicate with
non-existing modules.

In the COMM. menu there are three communication
options. In units with PC375 communication boards
(before 2006) the first option should be selected,
TCP/IP Comm. Board. On units with PC575 boards,
which appeared from the beginning of 2006, the
second option should be selected – PC575. WING
will work with both options, and the third option,
WING communication, should not be used. It is
designed for special units without communication
cards only.

Power+ Technical Guide 79

Gamatronic Electronic Industries Ltd.

10. SYSTEM CONTROLLER & COMMUNICATIONS

10.1 INTRODUCTION

The SCC POWER+ controller enables you to control and monitor all the individual components
of the POWER+ system. Flexibility in setting the various configurations allows you to adjust the
system to suit specific individual needs.

The system is equipped with clear, simple, user-friendly menus and submenus for easy
monitoring, parameter definition and control of the system. The SCC provides communication
with a wide range of management equipment, such as computers and mobile phones.

10.2 SCC POWER+ CHARACTERISTICS

The controller’s main functions include:

y Real-time 32 alarm display

y Manual and periodic battery testing

y An event log that records recent 254 events

y Service utility software

y Remote control of the system (via TCP/IP, SNMP, PPP, GSM, GPRS, SMS,CDMA).

y Three levels of access to the controller: factory, supervisor and service

y Easy restoration of factory defaults

y Easy setting and saving of user defaults

y Flexible output dry contacts

y Manual bypass command

y System turn off with or without bypass

80 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

10.3 CONTROLLER USER INTERFACE

The controller’s user interface includes:

y 40 × 4 LCD panel

y 6 Navigation Keys

y 3 Quick Command Buttons

y 8 Indication LEDs

y 2 Communication LEDs

10.4 SERVICE UTILITIES

There are several service programs intended for higher-level users (i.e. technicians,
maintenance staff, etc.).

These programs allow canceling and performance of low-level operations in the system at the
same time. These operations are complex and can modify the system configuration, affecting
its operation. The service utilities should only be used by authorized personnel.

These service utilities allow the operator to:

y Change configuration

y Manually turn off and on UPS

y Test dry contact outputs

y Switch to alternative version of the software

y Change communication settings

y Restart the controller

y Restart the network adapter

10.4.1 START-UP SCREENS

The welcome screen is displayed for a few seconds when the controller is switched on or
restarted, and is immediately followed by a self-check test.

On completion of the self-check test the initializing screen appears and remains on display until
the controller’s restarting process is completed. The software’s version is shown on the second
row. The time remaining in the restart process appears on the fourth row of the screen. The
main screen appears once the initializing screen closed.

The main screen provides the basic and essential information about the real-time status of the
power system. The LED indicator lights located to the right of the screen, warn if there is a
problem. The main menu remains displayed until one of the keys is pressed. The controller
automatically returns to this main menu screen whenever a key is not pressed for five minutes.

Power+ Technical Guide 81

Gamatronic Electronic Industries Ltd.

The following information is displayed on this screen:

y DATE - Current date
y TIME - Current time
y AC-VOLT - System input voltage from mains
y AC-CURRENT - System input current from mains
y AC-Output Voltage – System output voltage
y FL - Number of the active flash
y PD - Peripheral device status
y UP – UPS general status

From the main screen you can navigate to:

y The Fast Information Menu through which you can access the 7 Fast Information screens
y The Main Menu from which you can access:

y Monitor Screens that let you monitor the system and components

y Calibration Screens that let you calibrate the system and components

y Control Screens that let you control the system and components

Fast Information Screens

In addition to the many screens displaying detailed information about all aspects of the system,

there are seven Fast Information screens that contain further details about the real-time status
of the system. These screens can be accessed from the Fast Information Menu.

Network Fast Information Screen

This screen provides information about network related parameters such as the IP address, the
gateway address and the mask.

There is also a counter that shows the number of times the controller failed to connect with the
server. The maximum value that the counter can display is 225. Under normal operating
conditions the value should be 0.

There is also a count of the number of times there was no SNMP link. This value resets the
Network card.

Dry Contact Fast Information Screen

This screen provides real-time data on the status of the input and output dry contacts.

For both input and output dry contacts:

y A filled circle appears when the dry contact is closed.

y An unfilled circle appears when the dry contact is open.

82 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

System Alarm Status Fast Information Screen

This screen shows the status of the existing system faults, indicating whether or not they are
active. This screen shows:

y A filled circle indicates an active fault.

y An empty circle indicates an inactive fault.

General Information Screen

The following table describes the information displayed on the Information screen:

Table 10-1: General information screen

FIELD DESCRIPTION
REV

T.C.
V-SET
MAINT
V-AUX
SITE
BATT

Software revision number

Temperature

Output voltage

Last maintenance date

Input Voltage

ID number of the site

General battery information

Power+ Technical Guide 83

Gamatronic Electronic Industries Ltd.

10.4.2 THE MAIN MENU

The Main Menu enables you to access screens that monitor and control every aspect of the

system including setting parameter limits, activating the system checks and monitoring the
status of individual components of the system.

The Main Menu functions are listed in

Table 10-2: Main Menu functions

Screen Description
0 SYSTEM

1 UPS
2 SELFTEST
3 HISTORY
4 BATTERY
5 ALARM
6 SETUP
7 COMMS

Monitoring the System

Monitoring UPS

Initiates a Self Test of the Controller

Event Log

Monitoring the Batteries

Monitoring the Alarms

Submenu for setting parameters and starting tests

Communication (not implemented)

Table 10-2 below.

84 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

11. SETUP PROCEDURES

The options in the Setup Menu enable you to configure system parameters.

Table 11-1: Setup Menu options

Option Description
1 ALARM SET

2 UPS
3 BATTERY
4 CHARGE
5 TIME
6 SITE
7 PASSWORD
8 SERVICE
9 SILICON

Opens menu with options for setting the threshold levels that
trigger alarms

Sets the UPS Parameters

Sets the Battery current parameters

Sets the Charge mode parameters

Sets the systems clock which sets a time stamp on log entries

Sets the power system's ID number

Sets Level 1 Password

Opens menu of service utility programs

Opens menu with options for restoring factory-defined default
values to parameters

11.1 SETTING ALARM THRESHOLDS

It is possible to define the threshold values for setting off alarms for the parameters of system
components. An alarm is set off each time a parameter value is outside the defined range of
permitted values.

Press the number that appears beside a menu option to open a screen in which you can set the
alarm thresholds for that option.

Table 11-2: Setting alarm thresholds

OPTION DESCRIPTION

0 AC VOLT

1 OUTPUT VOLT

6 BATTERY

7 TEMPERATURE

8 VIBRATION

9 INTEGRATION

Sets the permitted AC voltage range (minimum and maximum input
voltage) and the AC voltage hysteresis

Sets the permitted DC voltage range (minimum and maximum
output voltage)

Sets the permitted battery voltage range (minimum and maximum
output voltage) (indicates possible battery fault)

Sets the permitted battery temperature range (minimum and
maximum temperature)

Sets the number of times an alarm must occur within a specified
period of time to be considered a vibrating alarm

Sets the number of times the controller must receive an alarm from
the system before it logs the alarm

Power+ Technical Guide 85

Gamatronic Electronic Industries Ltd.

11.1.1 SETTING ALARM VIBRATION PARAMETERS

A “vibrating” alarm is an alarm that is activated often. A vibrating alarm can fill a log with alarm
messages for the same alarm. To avoid filling the alarm with this kind of messages, you can
define a vibrating alarm (setting the number of times an alarm must occur as well as the period
of time in which it must occur).

11.1.2 SETTING THE INTEGRATION FACTOR FOR ALARMS

The integration factor is the coefficient that determines the number of times an alarm must
occur before the controller records it. The smaller the value of the coefficient is, the sooner the
warning notification is received. However, with a small coefficient there is a chance that an
alarm may be given for a glitch rather than a fault. The larger the value of the coefficient is, the
more notification is delayed and the greater the reliability.

11.1.3 'AUTO' TEST BATTERIES

The 'Auto' test option checks the periodic/automatic testing of the batteries.

11.2 SETTING PASSWORD LEVEL 1

A level 1 (supervisor) password allows you to monitor and control the system.

86 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

11.3 ADDING A POWER MODULE

If an additional shelf is attached at the top of the system, the DIP switch of the Control PCB
must be changed to the next address code as shown in

Updating the number of modules in the Power Plus processor:

(‘Ent’ represents a press of the Ent key.)

Ent, Setup,

Ent, Password (default password is 8 “left arrows” [½] ),

Ent, Service ,

Ent, Configure

Ent, Total # of UPS,

Table 3-3 on page 38.

Ent, (enter number of UPSs),

Ent , Ent

The system reinititializes itself.

11.3.1.1 TURNING OFF THE OUTPUT CURRENT LIMIT:

Ent, Setup,

Ent, Password (default password is 8 “left arrows” [½] ),

Ent, Battery,

Ent, Current Limit,

Ent, Enable current limit (off)

Esc.

Power+ Technical Guide 87

Gamatronic Electronic Industries Ltd.

11.4 SYSTEM CONTROLLER SETUP VERIFICATION

The system verification is available for software versions beginning from 050106.

11.4.1 ACCESS

Press ESCAPE key and hold it for 3S. Using ARROW UP/DOWN key, select GENERAL (8) and
press ENTER. Screen 1 is presented.

11.4.2 SCREEN 1

a) ACV: nominal value of the input/output AC voltage (220 for 2x32 batteries ; 110 for 2x16

batteries)

b) ALM: input AC voltage alarm HIGH/LOW

c) TEMP.ALARM: high temperature limit for external thermosensor
d) MODULES: QUANTITY/REDUNDANCY – 07/02 in the screen means that 7 modules are

presented in the system, 2 modules are reserve (full load is 10KVA*(7-2)=50KVA/40KW)

e) C.LIM.=off (VALUE)- battery current limit function is de-activated (off) or max. battery current

value in Amps. In C.LIM is activated, the system must be equipped with optional battery current
sensor.

f) T.C.=2.0mV – negative temperature coefficient of the battery DC voltage in mV per ºC per

battery cell. Nominal temperature is 25ºC. For DC nominal voltage 432V , temperature 35ºC, 32
batteries of 6 cells, T.C.=2mV, the voltage is 432- 2*6*32*(35-25)~=428V. NOTE. For most
applications T.C. must be 0 (off).

g) DCV: DC nominal voltage for both positive and negative battery sets. For 32 batteries in the set

DCV=432V, for 16 batteries 216V.

h) DCV …ALM: DC voltage alarms HIGH/LOW/SHUTDOWN. SHUTDOWN alarm is DC voltage

value when the unit is stopped due to battery discharge.

i) BATT….TEST: PERIOD IN WEEKS/MAX.DURATION IN HOURS/ALARM

VOLTAGE/CHARGER DERATED VOLTAGE. In the screen: the test is performed automatically
once per 4 weeks, max. test duration is 5 Hours, if battery voltage drops below 360V alarm
Battery Low is given, the chargers of the modules continue to supply voltage 352V to prevent
shutdown if battery is faulty.

j) CAP: CAPACITY in Amp-Hours. Is used to calculate estimated back up time of the system and

battery test duration.

88 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

11.4.3 SCREEN 2

To access SCREEN 2 press the key ARROW RIGHT when SCREEN 1 is selected.

a) #OF PHASE: FORCE 3 for 3 phase output, FORCE 1 for single phase output or AUTO when the

mode is defined by DIP SWITCH of the modules.

b) REV: revision of system controller’s (SC) software

c) LVD BY AC FAIL: DIS (disabled) or EN (enabled). This function, if enabled, performs system

shutdown after 3 Hours of AC failure to prevent deep battery discharge by low current. In most
application the function must be DIS.

d) MAINT: YEAR.MONTH.DAY: date of last maintenance

e) TEMP. SENSOR: DIS or EN . External thermosensor is disabled/ enabled. In most applications

must be DIS.

f) SITE: the site identification number. Is used in network applications.

g) CURR.SENSOR: DIS or EN. Optional battery current sensor is disabled/ enabled. In most

applications must be DIS.

11.4.4 SCREEN 3

To access SCREEN 3 press the key ARROW RIGHT when SCREEN 2 is selected.

The screen presents status of controller board’s jumpers. See also section
controller card" beginning on page

a) Not HARD Silicon. Must be HARD only initially, during first activation of non-configured

controller. After production should be Not HARD Silicon.

b) Silicon Mode. Regular mode allowing setups change. The setups are saved in EEPROM chip.
c) CAPACITY HI (LO). High/low battery capacity mode when battery capacity is more/less than

100AH to achieve optimal resolution of battery current displayed value.

33 for more information regarding these jumpers.

3.7.1 "PC714 – the

d) No/Yes Rmt Pan. Outputs of SC are not configured/ configured for optional remote panel

connection.

e) AC: 220V. Nominal AC input voltage: 220V for 2x32 batteries, 110V for 2x16 batteries in series.

Power+ Technical Guide 89

Gamatronic Electronic Industries Ltd.

12. REPLACEMENT PROCEDURES

12.1 UPS MODULE

To remove a UPS module from the system:

1. Unscrew the mounting screws on both sides on the front module panel.

2. Hold the front handle of the module and remove it by pulling out.

3. If the module is being permanently removed, update the total amount of modules in the system
controller.

WARNING: Do not touch or short-circuit metal pins on rear plugs of the module, as they might still be

energized. Let the module discharge for at least 15 minutes prior to any operation or disassembly.

NOTE: Other UPS module’s operation will not be affected by this removal, unless the load will become

too high for them with less power in total. For instance, if the load is 25Kva and one module out of three
was removed, the system might switch to bypass due to overload of the remaining UPS modules.

To insert a UPS module in to the system:

1. Insert the module firmly in to the housing and slide it in until it stops.

2. Screw the module in with two mounting screws located on the sides of its front panel.

3. It might be required to reconfigure the system controller with the new amount of modules in the
system

WARNING: Make sure that the module has the same configuration as other modules in the system. This

includes the dip switch settings (on the module itself) for frequency and number of output phases, as well
as the internal output voltage configuration, like 240v or 230v, which can be changed through the system
controller only. If the UPS module configuration will diverse from other module’s configuration, this
and/or other modules might be damaged.

NOTE: If the Power+ system was energized during module’s connection, the module will switch on

automatically within one minute. This will not affect other modules or the load.

90 Power+ Technical Guide

Gamatronic Electronic Industries Ltd.

12.2 SYSTEM CONTROLLER MODULE

To remove a system controller module from the system:

1. Ensure that there are no cables connected to the rear plugs of the controller. If there are any,
disconnect them prior to controller removal. This includes LAN cable and the WING (optional)
connections.

2. Unscrew the mounting screws on both sides of the system controller and pull it out of the
housing.

NOTE: Controller removal will not affect module’s operation and the load. Every module has its own

internal control and will keep up with proper operation, like current sharing and battery charging. Some
functions will not be available while the system controller is removed: battery test, battery conditioning
systems etc.

To insert a system controller module in to the system:

1. Confirm that the rear cables/plugs (if any) will not hinder the process; take them out of the
housing.

2. Hold the controller firmly and slide it in to the housing.

3. Screw the controller in with two mounting screws located on both sides of its front panel.

4. Connect rear external cables (if any) including LAN and WING (optional) connections.

5. If the controller was replaced with a new one, make sure that its configuration matches the
system with number of modules, battery settings, etc.

WARNING: If the controller is not properly configured for the given Power+ system, it might produce

false alarms and incorrect DC voltage handling.

NOTE: If the system was energized, the controller will start automatically within one minute.

Power+ Technical Guide 91

Gamatronic Electronic Industries Ltd.

12.3 STATIC SWITCH MODULE

To remove a ST/SW from the system:

1. Switch the entire Power+ system off, including input power and the batteries.

2. Unscrew two mounting screws on both sides of the ST/SW front panel, and slightly pull it
out, not more than 20cm.

3. Disconnect:

A.

Communication flat cable (mounted with 2 screws)

B. EPO/dry contact connections (if any)
C. 9 phase wires from the terminals (marked according to their order)
D. 1 neutral wire from its terminal
E. 1 earth wire from a dedicated screw

4. Pull the ST/SW module out from the system.

WARNING: This operation is not possible to perform live, without load and Power+ system

disconnection. The system should be switched off completely. Ensure that there are no AC voltages on
the terminals. If another ST/SW module will not be mounted immediately, all disconnected wires should
be isolated to prevent accidental damage and protect from electrocution.

To connect a ST/SW in to the system:

1. Make sure that there are no AC voltages on the system’s terminals and that the system is
switched off completely.

2. Slide the ST/SW module into its housing.

3. Connect in opposite order to it’s disconnection (above).

92 Power+ Technical Guide