Eltek UPC3

DC Controller
UPC3 & UPC3S

USER MANUAL
UM_UPC3_E_R03
Controller
UPC3
V1.19.159
User Manual
Page 2 of 54
Notes to this manual
ATTENTION! Please read this manual very carefully before mounting and commissioning the universal power
controller unit UPC3.
This manual is a part of the delivered device. Knowledge of this document is obligatory to use the specified
unit.
The rules for prevention of accidents of the specific country and the universal safety rules according to IEC
364 have to be observed!
The universal power controller unit UPC3 has been manufactured according to valid DIN- and VDE-standards,
such as VDE 0106 (part 100) and VDE 0100 (part 410). The CE-label on the module confirms the compliance
with EU-standards for 73/23 EWG – low voltage and 89/339 EWG – electromagnetic compatibility if the
installation and operation rules are observed.
Supplier:
Eltek Valere Industrial GmbH

Im Obrock 33
D-32278 Kirchlengern
+ 49 (0) 5223 7641-210
FAX + 49 (0) 5223 7641-222
Email Info.industrial@eltekvalere.com
Internet http://www.eltekvalere.com
 Copyright ELTEK VALERE INDUSTRIAL 2007. All rights reserved.
ATTENTION!
The duplication reproduction and/or adaptation of this document by electronic or mechanical methods, also
in parts, requires the previous authorization of the Convertronic GmbH.
ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

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Current revision status of the UPC3 user manual
Revision: /03
Datum: 18.01.2008
Revision Description Writer Date

Translation of the German edition “Bedienhandbuch
/00 RTH 08.02.2007
UM.UPC3.D.REV05” plus table “tech. spec.”
/01 Correction „ambient temperature“ RTH 06.03.2007
Correction „Inverter“ in place of “Rec” in switch OFF
/02 CF 22.06.2007
via CAN bus (Threshold).
/03 ELTEK VALERE Layout, technical data updated RTH 18.01.2008

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Contents
Safety Instructions/Waste Disposal Rules .......................................................................................................................6
Universal Power Controller UPC3........................................................................................................................................7
1.1 Technical Description .......................................................................................................................................7
1.2 The Concept .......................................................................................................................................................8

1.2.1 System monitoring and controlling................................................................................................................8
1.2.2 Temperature controlled output voltage.......................................................................................................8
1.2.3 Charge current limitation .................................................................................................................................8
1.2.4 Unregulated output voltage............................................................................................................................9
1.2.5 PLD function (Power load disconnect)...........................................................................................................9
1.2.6 LVD function (Low voltage disconnect) ........................................................................................................9
1.2.7 Battery asymmetry ...........................................................................................................................................9
1.2.8 Battery test ..................................................................................................................................................... 10
1.2.9 Battery test data memory............................................................................................................................ 10
1.2.10 Boost charge ................................................................................................................................................. 11
1.2.11 Monitoring of the power supply capacity utilization............................................................................. 11
1.2.12 Monitoring of redundant power supplies ................................................................................................ 11
1.3 Measurement inputs...................................................................................................................................... 12

1.3.1 Voltage measurement inputs ...................................................................................................................... 12
1.3.2 Current measurement inputs....................................................................................................................... 12
1.3.3 Temperature measurement inputs............................................................................................................. 12
1.3.4 Measurement range monitoring .................................................................................................................. 12
1.4 Quantity of the rectifiers: adding, removing............................................................................................. 13
1.5 Alarms............................................................................................................................................................... 13
1.5.1 Internal alarms ................................................................................................................................................ 13
1.5.2 External alarm inputs..................................................................................................................................... 13
1.5.3 Alarm signalling outputs ............................................................................................................................... 13
1.5.3 Failure list ......................................................................................................................................................... 14
1.5.4 Event list........................................................................................................................................................... 14
1.6 Display .............................................................................................................................................................. 14
1.7 Operating elements ....................................................................................................................................... 15

1.7.1 Change of display (leaf through the displays) .......................................................................................... 15
1.7.2 Change of the menu....................................................................................................................................... 15
1.7.3 Alteration of numerical values/assignments ........................................................................................... 15
1.7.4 Saving of altered values................................................................................................................................ 16
1.8 The menu ......................................................................................................................................................... 16

1.8.1 Measured values............................................................................................................................................. 16
1.8.2 Operating status............................................................................................................................................. 17
1.8.2.1 Event list..................................................................................................................................................... 18
1.8.2.2 Failure list ................................................................................................................................................... 19
1.8.2.3 Operating status battery test ............................................................................................................... 19
1.8.2.4 Operating status modem ........................................................................................................................ 19
1.8.3 Control function .............................................................................................................................................. 20
1.8.3.1 Control function battery test................................................................................................................. 21
1.8.3.2 Control function boost charge............................................................................................................... 21
1.8.3.3 Control function modem internal/external ......................................................................................... 21
1.8.4 Secondary menu (2nd menu) ....................................................................................................................... 22

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1.9 Communication Interface ............................................................................................................................. 23
Configuration – UPC3.......................................................................................................................................................... 24
2.1 In General ......................................................................................................................................................... 24
2.2 Configuration via a serial interface for systems with external modem.............................................. 24
2.3 UPC3 Parameter Groups ............................................................................................................................... 25

2.3.1 Table of the UPC3 parameter groups:........................................................................................................ 26
2.4 Configuration of the UPC3............................................................................................................................ 28

2.4.1 Basic settings UPC3 – 48V system ......................................................................................................... 30
(1) Main set:...................................................................................................................................................... 30
(2) CAN devices count.................................................................................................................................... 31
(3) Comb parameters ..................................................................................................................................... 32
(4) Battery ........................................................................................................................................................ 32
2.4.2 Location specific parameters....................................................................................................................... 33
(1) Installation.................................................................................................................................................. 33
(2) Ethernet module ....................................................................................................................................... 34
(3) UPC3 ............................................................................................................................................................ 34
2.4.3 Measuring system .......................................................................................................................................... 35
(1) Assignment shunt..................................................................................................................................... 35
2.4.4 Thresholds ....................................................................................................................................................... 36
(1) Threshold values....................................................................................................................................... 36
(2) Main set....................................................................................................................................................... 36
(3) Thresh. gen. par......................................................................................................................................... 37
2.4.5 Alarm signalling............................................................................................................................................... 37
(1) Digital inputs .............................................................................................................................................. 37
(2) Signals enable............................................................................................................................................ 37
(3) Signals switching mode ........................................................................................................................... 38
2.4.6 LVD/PLD function...................................................................................................................................... 39
2.4.7 Special Functions............................................................................................................................................ 40
(1) Enable.......................................................................................................................................................... 40
(2) Battery test................................................................................................................................................ 41
(3) Store battery test data ........................................................................................................................... 41
(4) Boost charge.............................................................................................................................................. 41
(5) Counter cells .............................................................................................................................................. 41
(6) MODBUS module ....................................................................................................................................... 42
(7) Mains monitoring....................................................................................................................................... 42
(8) Modem......................................................................................................................................................... 42
2.4.8 UPC3 Enabling of signalling/text ................................................................................................................ 45
(1) Text digital inputs ..................................................................................................................................... 45
(2) Enable display............................................................................................................................................ 45
2.5 Parameters which only get active via a restart....................................................................................... 46
2.6 List of failure bits/signal bits of the UPC3................................................................................................ 46
2.7 Technical Specifications UPC3 & UPC3S (S= small version) .................................................................. 53
2.7.1 Dimensional drawings UPC3 & UPC3S .................................................................................................. 54

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Safety Instructions/Waste Disposal Rules
Warning!
Due to the fact that several components of operating electrical devices are charged by dangerous
voltage, the improper handling of electrical devices may be the cause of accidents involving injury,
electrocution or material damages.
• Maintenance and handling of electrical devices must be executed by skilled personnel like
electricians according to EN 50110-1 or IEC 60950.
• Before starting work the electrical device must be disconnected from mains. Make sure that it is
earthed.
• Only spare parts approved by the manufacturer must be used.
All electric devices have to be decontaminated separately from the domestic waste at collecting points
which have been accounted from the government or municipal authority.
The accurate waste disposal and separate collection of rejected electric devices is the precondition to
recycle rejected electric devices and helps to prevent detrimental effects on human health and the
environment.
Above statement according to the directive 2002/96/EC applies to all electric devices installed in EU
countries.
In countries outside the EU may apply different rules regarding waste disposal of electric devices.
For detailed information regarding waste disposal of your rejected equipment please contact your Eltek
Valere partner.

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Kapitel 1
Universal Power Controller UPC3
1.1 Technical Description

All inputs and outputs of the UPC 3, as well as the CAN - Bus und power supply connections are
connected by a 64 pole plug-and-socket connector, which is at the back of the device (DIN 41612, Type
of construction: C64)
The digital inputs and outputs of the UPC3 are carried out as floating free. Data which causes an alarm
according to their configuration are saved and displayed as a fault, as long as they are active.
Additionally, the data is saved with date and time in the history list.
The analogue measuring inputs are placed on the analogue inputs of the processor. The measurement
values are displayed in the respective menu, the thresholds are monitored and an alarm is created in the
case of an over ride or dropping below the system values, according to the active UPC3 configuration.
The application program and the default values are stored in a flash memory. In this way it is secured
that the basic functions are retrievable even with the loss of customer specific adjustments (failure of
the rewritable memory) after a restart of the UPC3.
The UPC3 is equipped with a battery buffered real-time clock and a processor monitoring unit
(Watchdog), which monitors the power supply of the processor.
The buffering of the real-time clock is realised via a lithium-manganese coin cell CR2032. If the UPC3 is
stored at dead-voltage, the durability of the CR2032 is for at least 10 years. At operating conditions the
durability is nearly unlimited. Due to this fact a change is not necessary and therefore the coin cell is not
designed for a change.
The RS232 interface which is located on the front plate is free floating. The interface is designed for the
connection of a PC or a modem for programming or data transfer.
Furthermore the CAN bus interface for the control, programming and monitoring of the connected
modules is carried out via the 64 pole plug-and-socket connector.
The power supply is carried out as a DC/DC converter and supplies the system with the necessary
voltages.

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1.2 The Concept

1.2.1 System monitoring and controlling
The UPC3 is equipped with analogue inputs which serve for the measurement of the different system
voltages and currents. Furthermore the unit is equipped with digital inputs at which the condition of the
switch contact is monitored (closed or open). Additionally, the data of the modules (e.g. rectifiers) which
are connected to the CAN bus is collected. According to the UPC 3 configuration the data is displayed,
monitored and analysed.
Furthermore the modules which are connected to the CAN bus are controlled and monitored and if
necessary an alarm is created according to the respective UPC 3 configuration.
1.2.2 Temperature controlled output voltage

(Float charge of batteries in backup systems)
In this operation mode, the battery

U [V]
temperature is measured via a sensor and
is analysed by the UPC3 and adjusted
accordingly to a preset temperature
characteristic line. The output voltage of
the rectifiers is measured via the CAN bus
and regulated accordingly. This
characteristic line proceeds in an
adjustable range e.g. 0°C…40°C linear and
is constant beyond this range (see
illustration). The steepness of the
characteristic line is adjustable. The
charge voltage difference of a lead acid
battery is -5mV per cell and per °C by
default.
0°C 20°C 40°C T [°C]
1.2.3 Charge current limitation

Discharged batteries, e.g. after a backup
operation, are charged with an adjustable
maximum current until the trickle charge,
controlled by the temperature, is reached.
The battery voltage is measured at the
beginning of the battery charging.
Commencing with this battery voltage, the
output voltage of the rectifiers is
respectively increased so that the set
maximum of the battery charging current
is reached. This process is retained as long
as the output voltage has reached the
value of the trickle charge (controlled by
the temperature).

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1.2.4 Unregulated output voltage

(Autarkic operation)
If the rectifiers do not get a control signal, e.g. because of:

• Failure of the UPC3,
• Break of the CAN bus connection,
the rectifiers self-acting return to an output voltage of 54.5 V, constant. At backup systems with
connected batteries this mode of operation should be seen as an emergency operation.
1.2.5 PLD function (Power load disconnect)

There is the possibility to disconnect up to two consumer loads (inferior priority load) independently from
each other in order to save battery capacity during the backup operation.
The disconnection criteria are selectable independently from one another:
• Disconnection after falling below an adjustable voltage threshold, reconnection after exceeding
the adjusted voltage threshold
• Disconnection after expiration of an adjustable time after recognition of a battery operation.
Reconnection at ending of the battery operation.
• The activation of the PLD contactors can be realised via the optocoupler or any of the internal
relays of the UPC3.
1.2.6 LVD function (Low voltage disconnect)

For the protection of the connected batteries against total discharge during back up operation a
voltage threshold can be adjusted. If the threshold value is reached the LVD contactor switches off.
The activation of the LVD contactor can be realised via the optocoupler or one of the internal relays
of the UPC3.
1.2.7 Battery asymmetry

It is possible to monitor the battery symmetry voltage in order to locate faulty batteries in a battery
string.
In addition, a voltage (symmetry voltage) is measured at the centre of the battery string and compared
with the complete battery string voltage.
The symmetry voltage amounts to ½ of the complete battery string voltage, if the connected batteries
are without fault.
If the symmetry voltage deviates more than an adjustable value of ½ of the battery string voltage an
alarm is activated via the UPC3.

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1.2.8 Battery test

The battery test serves for the inspection of the batteries as well as for the inspection of the faultless
connection to the batteries.
This test can be performed manually at the UPC3 display, via SNMP or via the configuration software as
well as periodically with an adjustable interval (start date / time, repetition interval in days).
The rectifiers’ voltages are reduced to an adjustable voltage value during the battery test.
ATTENTION! This voltage value has to be greater than the voltage threshold of the
LVD/PLD function. Otherwise the load supply could be disconnected during
the battery test if the batteries are faulty.
Thereby, the batteries supply the connected load and therefore will be discharged. Adjustment criteria
of the battery test are:
• test duration
• the minimum allowable battery test voltage
• the maximum battery capacity to be withdrawn in %
The battery test is assessed as faulty and a respective alarm is activated, if the minimum test voltage
has been achieved within the test duration or the maximal battery capacity has been withdrawn. After
the end of the test duration or after an identification of a faulty battery the rectifiers are set back to the
default value relating to the battery charging current limitation.
An activated alarm of a battery test failure can be cancelled via a reset of the UPC3, via the UPC3 menu
or via an anew execution and faultless completion of the battery test.
1.2.9 Battery test data memory

Via the data memory the data can be recorded during a battery test and later be analysed by a PC (UPC3
configurator) which is connected to a RS232 interface. The following is recorded automatically during
any battery test:
• Start- und stop time of the battery tests
• Duration of the battery tests
• The activation of the battery tests (manually or automatically)
• The withdrawn capacity during the battery tests and the measured battery voltage at the end
of the test
• The data of the battery type, date of the battery installation and the nominal battery capacity
(this data is retrieved from the entered data in the main menu).
The above described (head) data are saved at any one time for the last three battery tests.
Additionally the following data of the last battery test is saved:

• Number of the generated data set
• The elapsed time of the battery test (hours, minutes, seconds)
• The particular battery voltage and the battery symmetry voltage
• The particular battery current
• The particular battery temperature
Due to this facts detailed information are available at the end of the test.

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1.2.10 Boost charge

For a rapid recharge of the battery (only ventilated batteries) a boost charge mode is available. The
boost charge mode can be activated manually via the user or self-acting (e.g. if a mains breakdown
occurred).
During the boost charge mode the battery voltage is increased to a greater value than the trickle charge
voltage. Furthermore a considerably greater battery charge current is defined for the duration of the
boost charge mode. If the defined charge voltage value is reached, a follow up charge duration starts.
After the expiration the boost charge voltage automatically is decreased to the value of the trickle
charge voltage.
The boost charge mode can be started via the buttons of the UPC3 and if necessary be stopped before
the defined boost charge time has been elapsed.
1.2.11 Monitoring of the power supply capacity utilization

With the help of this function it is possible to monitor the capacity utilization of each individual rectifier.
In addition to this, a changeable adjustable threshold (%) is set that relates to the nominal current of
each rectifier. This threshold is valid for all rectifiers.
The output power of the units will not be changed by this and remains at 100%.
For example:
REC load limit set to 50%

Nominal current of each rectifier 50A
Due to this, the load limit of each rectifier is equal to 25A
The UPC3 generates an alarm “REC load” if a higher current is withdrawn.

The load limit of the whole facility is determined in the following way: The number of the installed
rectifiers is multiplied with the load limit of each rectifier.
For example:
4 installed rectifiers = 4 x 25A load limit of each unit = 100A load limit of the whole facility.
1.2.12 Monitoring of redundant power supplies

Excessive rectifiers can be configured as redundant if the facility is equipped with more than enough
rectifiers (redundancy). All rectifiers within the facility remain active, merely the signalling would be
changed in the case of an unit failure.
For example:
The facility is equipped with 3 rectifiers, 1 unit is configured as redundant:

The UPC 3 generates an alarm „REC redundant“, if one unit fails.
For example this alarm could be classified as not urgent because the efficiency of the facility is not in
danger with the failure of one unit because there are more units available than really necessary
(redundancy).

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1.3 Measurement inputs

The UPC3 serially is equipped with following measurement inputs:
• 3 x voltage 0-60V (48V version)
• V1 and V2 act as power supply
• 3 x current 60mV shunt
• 2 x temperature sensor KTY81-220
1.3.1 Voltage measurement inputs

The particular measurement range of all voltage measurement inputs amounts to 0 - 60VDC (48V
version). The allocation of the voltage measurement inputs at the UPC3 is the following:
• V1 Battery voltage (supply 1)
• V2 System voltage (supply 2)
• V3 Tapped battery voltage for the measurement of the battery asymmetry (Batt/2)
1.3.2 Current measurement inputs

The measurement range of the input I1 amounts to ±60mV (bidirectional). The measurement ranges of
the inputs I2 and I3 amount to 0-60mV (unidirectional).
1.3.3 Temperature measurement inputs

The temperature measurement inputs are designed for the use of the sensors of the type KTY81-220.
Via presetting, the temperature measurement input 1 is allocated to the battery 1 (temperature
compensation).
1.3.4 Measurement range monitoring

The voltage measurement inputs can be monitored with the setting of changeable thresholds within a
certain range.
The UPC3 generates an alarm if the voltage deviates from the adjusted parameters. Due to this fact,
overvoltage and undervoltage alarms are realisable.
For the system voltage/consumer load voltage two thresholds are adjustable:
Vload > Vmax and Vload < Vmin
For the battery voltage three thresholds are adjustable:

Vbatt > Vmax, Vbatt < Vwarn and VBatt <Vmin
For the battery current no range monitoring is available. For the load current a “load current limit” is to
adjust. If the limit is exceeded a failure bit is generated.
For the temperature measurement inputs a failure bit is generated if T > Tmax. A further failure bit
signals a defective sensor (e.g. cable break or short circuit).

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1.4 Quantity of the rectifiers: adding, removing

The quantity of the rectifiers which shall be monitored can be adjusted manually during the configuration
of the system. Should a further rectifier be added at a later date, this unit automatically will be applied at
the UPC3 and integrated within the system.
But the removing of a rectifier generates an alarm. For the abolition of the alarm either you have to
change the number of the rectifier quantity or the item „REC default ok“ has to be processed via the
UPC3 system menu.
1.5 Alarms
Within the configuration of the UPC3 you are able to define which failure bits shall activate an alarm (e.g.
over-/under voltage, rectifier error, fuse fall etc.).
Alarms which are registered within the error list are signalled via a blinking error LED. Furthermore at the
display the notice “ERR” is shown.
Attention: Actual alarms only can be deleted by fault repair.
It can be distinguished between two kinds of alarms:

• Internal alarms
• External alarms.
1.5.1 Internal alarms

Internal alarms are directly reported by the UPC3, e.g. failures signalled via the CAN bus or by excess or
shortfall of alarm thresholds.
The designations (failure text) of internal alarms are set by default in the program and cannot be
changed.
1.5.2 External alarm inputs

External alarms are recognised via the digital alarm inputs. At those inputs it is monitored whether or not
a connected contact is closed or open. By reversing of the inputs it can be determined whether an alarm
is activated at an open or closed contact.
The designations (clear text) of the external alarms can be entered or changed individually (max. 16
characters).
The UPC3 is equipped with 8 integrated alarm inputs. Those digital inputs 1.1 up to 8.1 are freely
available for the user. The optional connection of an external DCC-DIG8 module to the CAN bus extends
the system with further 8 alarm inputs (digital inputs 1.2 up to 8.2).
1.5.3 Alarm signalling outputs

For external fault signalling the controller is equipped with 6 internal relays (UPC3 configuration relay
1.1-6.1), each of them equipped with a free floating change-over contact. The optional connection of an
external DCC-RB6 module to the CAN bus extends the system with further 6 signalling relays (UPC3
configuration relays 1.2-6.2).
Each activated alarm can be assigned to a single or several signalling outputs. Likewise it is possible to
assign several activated alarms to a single signalling output. In this case the signalling relay remains
active until all assigned alarms are disappeared.
Whether the respective signalling relay is turned on or off during an alarm is adjustable via reversing.

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1.5.3 Failure list

Within the failure list all active failures (alarms) are shown at the display (clear text and an ID number
according to the definition in the program).
If a failure (alarm) is not active anymore it is not shown any longer within the failure list.
1.5.4 Event list

Within the event list all occurred failures are stored with the appearance and disappearance of the
failures as well as the date and time.
Attention: Leaving the event list the system requests whether the list shall be deleted or not. If
you want to delete: Enter code „988“.
If the memory is full (250 entries), the eldest failure is deleted and a new one is added.
1.6 Display
• The UPC3 is equipped with a green coloured front side display (two lines per 16 characters) with
backlight.
• Three LEDs indicate the state of the device and existing active alarms.
LED 1 green = UPC3 „ON“
LED 2 green = no active alarms, system „OK“
֠ LED 3 red = active alarms are existing

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1.7 Operating elements
The operation of the controller basically takes place via the 4 front side buttons (↑, ↓, ENT, ESC). The
function of each button depends on what is shown at the display and on the respective menu level.
Switch back to the particular Change to previous line/increase

superordinated menu without value
accepting and saving of
alterations.
ESC ENT
1. If the symbol „→“ is shown

you can switch to the
particular next sub menu. .
Change to next line/decrease 2. Accepts and saves altered
value input values
1.7.1 Change of display (leaf through the displays)
The change of the display takes place via pressing the buttons “↑↓“, whereas “↑“ changes to the
previous and “↓“ changes to the next display.
1.7.2 Change of the menu
Displays which include a selectable submenu are marked with the symbol „→“. By pressing the “ENT”
button you get the submenu. The return to the superordinated menu takes place via pressing the “ESC”
button.
1.7.3 Alteration of numerical values/assignments
In order to increase the value it is necessary to press the “↑” button and press the “↓” button for the
reduction of the value for alteration of a displayed value. The value is altered by the smallest possible
amount by pressing the buttons in single steps. If the button is pressed by holding it down, then the
values are changed continuously. The speed rate of change increases the longer the button is held
down.

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1.7.4 Saving of altered values
Altered values are accepted and saved by pressing the “ENT” button.
1.8 The menu
As a standard 4 menu blocks are available:

1. Measured values
2. Control functions
3. Operating status
4. System menu
1.8.1 Measured values

According to the configuration of the system, in this menu block the measured data of the system is
displayed.
Measured values:
• General: Current I3, temperature T2 and 4x general measurement values G1…4
• Mains: Voltage, current and frequency (only systems equipped with mains monitoring (MM)
board)
• Power modules: Rectifier, DC/DC converter, inverter, static bypass switch (e.g. output voltage,
output current, temperature)
• Power system: System voltage/-current, earth fault measurement (if activated) and the
calculated battery-, rectifier- and consumer load currents.
• Batteries: Battery voltage, -current, center voltage of the battery and temperature.

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UPC3 09.12.2006
OKAY 11:47:36
Output voltage of the Output current of the

X times particular module particular module
Measuring values Power Modules REC1: OKAY REC1: OKAY

→Power-Modules ENT →Rectifier ENT Vo = 54,5V ENT Io = 11,5A ENT
1X DC/DC-Converter,
Inverter, SBS
REC1: OKAY
Measuring values Ula: 54,5 T = 43°C
→Power-System ENT Ila: 21.0A
Temperature of the
1X
particular module
Shows the information of the
individual modules
Measuring values Ub1: 54,5
→Batteries ENT Ib1: 2.0A
1.8.2 Operating status

In this menu block information of the actual operating status of the system can be queried.
Operating status:
• Digital inputs: Status active/inactive of the digital inputs 1.1-8.1 (internal) and 1.2-8.2 (external
CAN). Active = active in signal matrix!
• Relay outputs: Status active/inactive of the relay outputs 1.1-6.1 (internal) and 1.2-6.2 (external
CAN). Active = Relay operates!
• FM board: Status active/inactive of the fuse monitoring board.
• Failure list: The failure list shows the actual errors.
• Event list: The event list shows all stored alarms (date/time, appearance/disappearance.
• Fan racks: Shows „Okay“ or „Failure“ of each of the connected fan racks.
• Battery test: Battery test active = ’*’, inactive = ’ -’. Furthermore the withdrawn capacity (Ah) is
shown.
• Store BTest data: Shows whether data currently are stored or not. ’ OFF/ON’
• Boost charge: Boost charge active = ’*’, inactive = ’ -’
• Modem: Shows the initialisation status of the external or internal modem.

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1.8.2.1 Event list
UPC3 11.12.2006
OKAY 11:47:36
X times
Shows the appeared alarm Shows the start of the

and the alarm ID no. alarm (date/time)
Operating Status
ESC
Ub1 > Umax(B1) 11.12.2006 Delete History?
→Event List ENT -> [56] #6 → ENT 8:11:26 No/Yes: ESC/ENT
ENT
ENT ESC
Back to:
1X
„Event list“
DC Fuse failure Ub1 > Umax(B1) 11.12.2006 Code Deleting:

←[32] <- [56] #6 → ENT 9:12:56 000
„Leaf“ trough the list Shows the end of the alarm After entering of a code you can
(Date/time) delete the list.

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1.8.2.2 Failure list

Alarm LED active and the
UPC3 11.12.06 notice „ERR“ on the display
ERR 11:47:36 indicate one or more failures
(alarms).
X times
Operating Status Ub > Umax (B1) Shows the active

ENT
→Failure List 56 failures (alarms)
Leaf through the list
1.8.2.3 Operating status battery test

Shows the withdrawn battery capacity
Operating Status * Manual
ENT during a running battery test
→Battery Test Cap.=12AH
1.8.2.4 Operating status modem
This menu is selectable if an internal or external modem has been enabled within the configuration of the
system. The modems are shown in the display via the identification code ‚Ext’ or ‚Int’.
OperatingStatus
→Modem ENT
Modem has not been started. Star-ting

Int: procedure of the modem see item
1.8.3.3
Modem has been started. The following

Int: .____0/+lI string elucidated the status. For details
see the followings.
Explanation of the modem status string:

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*____0=+lI
.caeo1/!?i
CAEO21>W
32w
43
54
65
76
87
9
#
^
Important is the first and the final character.
Meaning of the first character:
*= UPC3 communicates with the modem (e.g. sending of the initial string).
.= no communication with the modem
Meaning of the final character:
I= initialised
i= not initialised
During starting the UPC3 and during starting initialisation, the first character is “*”, the final character is
“i”.
After a time period the first character is “.”, the final character is “I”. This indicates a successful
initialisation.
1.8.3 Control function

In this menu block activated UPC3 functions can be executed.
Control function:
• Battery Test: Start/Stop Battery test, Battery test failure delete.
• Data memory: Output of the final series of measurements at the serial interface
• Boost charge: Start/Stop Boost charge
• Modem internal/external: Start/Stop internal/external Modem operation
• 2nd Menu: More system sub menus

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1.8.3.1 Control function battery test
ControlFunction Battery Test ENT Battery Test

→Battery Test ENT ↕→ Start?->ENTER
ESC ENT
Battery test
starts
Failure delete Failure delete

Test=1 → ENT Test=0
Active battery test fail. Failure deleted!
1.8.3.2 Control function boost charge
Control Function Boost Charge ENT Boost Ch. starts

→Boost Charge ENT Start?->ENTER
ESC gestartet!
1.8.3.3 Control function modem internal/external
Control Function Adjust modem

Modem Op.(ext) ENT operation
→Modem ext. ENT Stop?->ENTER
ESC
ATTENTION ! If a PC is connected to the RS232 interface for the configuration of the

system, an activated external modem has to be deactivated via this
function to get access to the system.

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1.8.4 Secondary menu (2nd menu)
Via the secondary menu the status and the configuration parameters of the UPC3 are visible and can be
changed (by entering of a protection code).
Control Function2nd Menu:

• Error list: All active present errors (failures)
• History list: The final 250 incoming and outgoing failures/events
• History list P: History list in the memory (flash) of the UPC3. (Not used).
• Config. UPC3: Configuration of the UPC3 hardware
o Date & Time
o Display backlight
o Display contrast
o Delete, Restart
o Delete NVmemHis
o Calibration
• Control function.: Control functions of the UPC3
• View System par: Display of the UPC3 configuration parameters
• Change System p: Change of the UPC3 configuration parameters
• View Measurepar: Display of all measuring values of the UPC3 (also via CAN)
Following adjustments are changeable in this menu without entering of a protection code:
1. Date and Time

2. Display backlight in %
3. Contrast of the display in %
Control function ENT →Error List

->2nd Menu History List
Change value
→Config UPC3 →Date&Time 11.12.2006
ENT ENT
Controlfunction Display backlig 11:47:36 ENT Save data
Change value
→Displaybackli ENT
Displaycontrast 70
ENT Save data
Change value
→Displaycontra ENT
Delete,Restart 100
ENT Save data

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1.9 Communication Interface

For the connection of a local PC to the UPC3 a serial interface is necessary (via a full wired null modem
cable). Of particular importance are the crossed data- (RxD/TxD) and handshake lines (RTS/CTS).
Pinfunktion:
Pin Designation Function

2 RxD Receive Data
3 TxD Transmit Data
4 DTR Data Terminal Ready
5 GND Signal Ground
6, 1 DSR, DCD Data Set Ready and Carrier Detect
7 RTS Request to Send
8 CTS Clear to Send
9 NC Not connected
Please connect the serial port of the PC to the RS232 connector at the front side of the UPC3 via the
above described cable.

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Kapitel 2
Configuration – UPC3
2.1 In General
Although a configuration in principle is possible directly via the UPC3 control buttons, it is advisable to
configure the system via the included PC software „UPC3 Configurator“.
For the connection of a PC the UPC3 is equipped with a communication interface RS232 at front side,
optional a connection via modem or Ethernet.
The configuration software works with the system software Windows 98SE/2000/XP. The user manual
for the dial-up and general operation of the software is optionally available.
2.2 Configuration via a serial interface for systems with

external modem
To configure the system with the configuration software with an external modem via the serial interface
please note the following:
Two different operational modes are possible.
1) External modem has been started.

Dial-up at the system is possible. The system can be configured via modem. In this case a configuration
directly via the serial interface is not possible.
2) External modem has been stopped.

Configuration via a serial interface is possible. Dial-up at the system via modem is not possible.
Please see the item 1.8.3.3 „Control Function Modem internal/external“ for the starting and stopping of
the modem. An explanation of the status of the modem can be found at item 1.8.2 “Operating Status”.
Basically please note following order:
1. Stop the external modem

2. Check whether the external modem has been stopped.
3. Disconnect the serial cable of the modem from the RS232 interface.
Connect the PC via Null Modem Cable to the UPC3.
4. Configuring of the system
5. Disconnect the Null Modem Cable, connect the serial cable of the modem.
6. Start the external modem
7. Check whether the external modem has been started/initialised

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2.3 UPC3 Parameter Groups
After a successful readout/start of a configuration a register of the 31 parameter groups is shown to

the left of the screen. A selected group (via the left mouse button) is shown to the right.
The parameter groups can be classified in system specific parameters and installation specific
parameters and can be stored accordingly as „*.mc2“ File (all parameters) or „*.syc“ File (system
parameters only).

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2.3.1 Table of the UPC3 parameter groups:
Parameter group *.mc2 *.syc description

Installation System description, e.g. location, service-no. etc.
Non effect to the system function!
UPC3 Specific set-up and information about the UPC3 e.g. serial-no,
language selection, LCD-contrast, illumination, etc.
Ethernet modul Set-up of the SNMP-agent e.g. IP-address, Gateway, Trap-
Receiver.
MODBUS_Modul Set-up of an optional MODBUS module
Main-set Set-up of battery charge regulator and to the batteries e.g.
battery type/-number, cell voltage/number of cells
Enable Release of spec. functions e.g. battery test or boost charge.
CAN Devices Cnt Number of the connected modules via CAN-Bus e.g. rectifiers,
analogue measurement inputs (XXA), fan racks, etc.
Assignment Measu Displayed only at start of the configurator with additional
parameter „/sys“. Allows the allocation of measuring channels
measuring objects (e.g. I1=Ibatt)
Assignment Shunt Assignment shunt value to the current measuring input
Special set Modification only in arrangement with the manufacturer.
Mains monitoring Set-up of mains monitoring via external mains monitoring
board (DCC-MMB)
LVD PLD Function Set-up of LVD/PLD function of the UPC3, e.g. switch-off-
/switch-on voltage
Digital inputs The eight digital inputs can be inverted and delayed
Signals enable Via setting of failure/event bits in a signal matrix it is possible
to activate an SNMP Trap (optional) or an alarm relay.
Signals Sw mode Signal switch mode, allows the inverting / delaying of outputs
Comb parameters The comb parameters set the important system adjustments
e.g. rectifier nominal voltage or min/max system voltage.
Thresh. Gen. par Set-up of the min/max limits for the general measuring values,
e.g. T2>60°C (room temperature high)
Thresholds Set-up of thresholds e.g. battery over-/under voltage, over
temperature etc.
Battery Set-up of battery parameters e.g. capacity, temperature
compensation, tapping (for unsymmetry measurement)
Battery Test Determines the switch-off condition of a running battery test.
Store BTest data Integral of measuring value for test data storage.
Boost charge Parameters of battery boost charge.
Counter cells Set-up of two optional counter cells, e.g. thresholds Von/Voff
of the signal bit of counter cell 1/2
Modem Set-up of optional modem
Enable display Deactivation of indications at the display of the UPC3
Text Digital inp Text input of the eight digital inputs of the UPC3. Appearance
e.g. in the error list.
Text Relays Text of relay/digital output of the UPC3. Appearance in the
display.
Text Batt param Text of display for battery parameters e.g. Vbatt
Text Comb param. Text of display for system parameter e.g. Vload
Text Gen. param. Text of display for general measuring values e.g. Tsensor2
Text Fuses Text of the 32 monitored fuses per optional fuse-monitoring-
board (CAN-FMB)

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Parameter group *.mc2 *.syc description

Module ID-texts Just display! Text of the CAN modules, e.g. REC1

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2.4 Configuration of the UPC3
This chapter describes the configuration of the UPC3. To improve the clarity the classification of the
several groups according to the following table has taken place.
Basic setting UPC3

Main-set Set-up of battery charge regulator (new) and to the batteries e.g.
battery type/-number, cell voltage/number of cells
CAN Devices Cnt Number of the connected modules via CAN-Bus e.g. rectifiers, analogue
measurement inputs (XXA), fan racks, etc.
Comb parameters Maximum charge current of rectifier (old), default values
(voltage/current) of the rectifier modules
Battery Set-up e.g. of: Battery capacity, activating/adjustment of the

unsymmetry measurement/temperature compensation
Location specific parameters

Installation Location, service no., contact person, etc.
The text has no effect on the system function!
UPC3 Only read: Serial number, firmware version, configurations date/person
Set-up: Language selection, screen contrast/-illumination, baudrate
USBtoUART
Ethernet modul Set-up of SNMP agent, e.g. IP address, gateway, trap receiver.
Measurement system
Assignment Measu Displayed only at the start of the configurator with the add-on
parameter „/sys“. Allows the assignment: Measurement channel to
measurement object (e.g. measurement channel I1.1 = battery current)
Assignment Shunt Assignment shunt value to the current measuring input (e.g. I1.1 = 80A
shunt)
Thresholds
Thresholds Thresholds of battery over/under voltage
Threshold of over temperature
Threshold of battery operation
Thresh. Gen. par Thresholds of general parameters e.g. XXA analogue measurement
input
Main-set Limit of the consumer load current
Alarm signalling
Digital inputs Inverting/delaying of the digital inputs
Signals enable Via setting of failure/event bits in a signal matrix it is possible to
activate an SNMP Trap (optional) or an alarm relay.
Signals Sw mode Signal switch mode, allows the inverting / delaying of outputs

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LVD/PLD
LVD PLD Function Set-up of LVD/PLD function of the UPC3, e.g. switch-off-/switch-on
voltage
Special features
Enable Release of spec. functions e.g. battery test or boost charge.
Battery Test Determines the switch-off condition of a running battery test. Set-up of
the start date of an automatic battery test.
Store BTest data Integral of measuring value for test data storage.
Boost Charge Conditions of an automatic boost charge, set-up “follow up charge”
(follow up charge time, voltage limit)
Counter cells Set-up of the counter cells
Mains Monitoring Relates to an external mains monitoring (MM-) board, optional
MODBUS_Modul Set-up of an optional MODBUS module, e.g. slave address, baud rate …
Modem Configuration of an internal/external modem
UPC3 Display / Text

Text Fuses Text for maximum 32 via fuse monitoring board (FMB) monitored fuses
Text Digital inp Text for the digital inputs of the UPC3. Appear e.g. in the failure list
Text Relay Text for relay outputs of the UPC3, shown at the display
Text Batt param Display text for battery measuring values, e.g. Vbatt
Text Comb param Display text for system measuring values, e.g. Vload
Text Gen. param Display text for general measuring values, e.g. Tsensor2
Module Id-texts Just display! Text of the CAN modules, e.g. REC1.
Enable display Deactivation of indications at the display of the UPC3

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2.4.1 Basic settings UPC3 – 48V system
(1) Main set:

3
The main function of the UPC3 is to
deliver a voltage default value to the
4 rectifiers, in order to charge batteries or
to keep them under well load conditions.
If the regulator enable (1) is set at zero
(regulator “old”), following applies:
5
Rectifier voltage =
default value normal charge
6 + regulator component(IBatt)
7 + temperature
8 compensation(TBatt)
In this case the regulator component
depends on the actual battery current
and the maximum charge current (2). If
2 1 the charge current exceeds the limit (2)
the rectifier voltage will be reduced
about 0,1 V per second.
If the regulator enable (1) is set to a value > 1, the regulator “new” is activated.
This regulator provides some additional features. After the restart of the system beginning with the
adjusted start voltage (6) the voltage arises (0,1V per second) to avoid current peaks, e.g. caused by
discharged batteries. The current regulator „new“ works in conjunction with the adjusted relative current
default value (3) or in the case of an active boost charge with the increased boost charge current (4). The
point of reference of the relative current default value is the nominal battery capacity (entered under the
parameter group “Battery”).
Under the parameter group “Comb parameters” the preset control-system acting time (0,1V per second)
additional can be delayed.
As already described the regulator normally reacts with a voltage change rate of 0,1V per second. This
applies too if the preset charge current has been exceeded. In this case the voltage will be reduced as long
as the actual value corresponds to the default value. But if the charge current exceeds the shock current
limit (5) the regulator abruptly reduces the rectifier voltage to a save level.
The inertia (7) and the REC resolution (8) have an effect on the control mode of the UPC3. Via increasing of
the inertia (7) the current regulator slows down reaching the maximum charge current. The setting of the
REC resolution (8) from 0,1V to 0,01V reduces the ripple of the battery current.
Regulator „Old“ → regulator enable = 0 Reglulator „New“ → regulator enable = 1

- Maximum battery charge current for normal - Maximum charge current normal charge (3)
and boost charge are identical (2) - Maximum charge current boost charge (4)
- Current shock (5)
- Charge current is independent of number and - The default values of the currents are
capacity of the battery depending on the number and capacity of the
batteries. Default values of the batteries in %
(3,4,5)
- Trickle charge voltage is the start value if a - Soft start-up! The start voltage is adjustable
mains fault has been occurred via the parameter „start voltage“(6)

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9 The UPC3 hardware (measuring inputs) is

designed for the monitoring of one
battery connected to the system. If
10b
several batteries are connected to the
10a system an external battery monitoring
board is needed. The parameter „Battery
Count“ (9) is adjustable according to the
number of the connected batteries.
At systems without connected batteries (Parameter=0) the charge regulator ant temperature
compensation is deactivated. The system operates with the set default value of the rectifier voltage.
Normally the battery string of a 48V system is built on a series connection of 4 lead acid batteries per 6
cells. Due to this fact the cell count (10a) amounts to 24 cells with a (nominal) voltage per cell (10b) of
2.00V/c. If either of the parameters has been changed, after a restart the UPC3 recognises “new voltage
version” and changes self acting the parameters according to the following table:
Parameter Value Default 48V System
Over voltage Vmax (50)/(55) 1,200 x number of cells x voltage per cell 1,200 x 24 c x 2,00 V/c = 57,6V
Under voltage Vmin (51)/(57) 0,900 x number of cells x voltage per cell 0,900 x 24 c x 2,00 V/c = 43,2V
REC nominal voltage VN (18) 1,135 x number of cells x voltage per cell 1,135 x 24 c x 2,00 V/c = 54,5V
Battery test Vbatt_test (19) 0,886 x number of cells x voltage per cell 0,886 x 24 c x 2,00 V/c = 42,5V
Boost charge Vboost (20) 1,198 x number of cells x voltage per cell 1,198 x 24 c x 2,00 V/c = 57,5V
Start voltage Vstart (2) 0,958 x number of cells x voltage per cell 0,958 x 24 c x 2,00 V/c = 46,0V
LVD/PLD voltage (72)(73) 0,000 x number of cells x voltage per cell 0,0V
ATTENTION! After the change of the voltage version the configuration

parameters have to be readout again!
11
(2) CAN devices count
The UPC3 can be connected to a

multitude of devices via the CAN bus.
For example 8 additional digital inputs
(DIG8) (13) or 6 relay outputs (RB6) (14).
The rectifier count can vary (11) in
12 different systems. Each marked field
corresponds to the CAN address of an
applied rectifier. Due to the fact that not
all of the slots must be equipped, gaps
within the sequence can occur.
13 14 In systems with redundant rectifiers an

additional alarm can be created via the
indication „Redundant REC” (12
Example: System with 7 applied rectifiers (11), the parameter “Redundant REC” (12) is set to “2”
REC1 fails: The signal bit „REC no CAN“ is activated! Still no redundancy failure!
REC2 fails: The signal bit „REC redundancy“ is activated! No more redundancy available!

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15 16 (3) Comb parameters

17 18
19 „RECNom voltage” (15) is equivalent to

the normal charge voltage without
20 temperature compensation. Parameter
(16) and (17) stand for the default values
21
of the voltages for battery test
24 respectively for boost charge.
23 The value “RECNom current“ (18) is sent
to the rectifiers via the can bus.
22 Normally this value is set according to
the specification of the type plate of the
rectifier.
The rectifier load limit „RECLoad limit“
(19) applies relating to the adjusted
nominal rectifier current “RECNom
current”.
Exceeding the load limit of a rectifier (e.g. 80% Inom), a signal bit “REC Load” is activated.
The parameters (20) and (21) offer the monitoring of the rectifier load distribution (just applicable in
systems with more than one rectifier). If the difference between the maximum and minimum rectifier
current amounts to more than e.g. 15% (21) of the nominal current of the rectifier “RECNom current” (18) ,
a failure bit is activated. Due to the fact that the load distribution at low charge of the system is worse, an
evaluation takes place only if the adjusted load limit (20) has been exceeded.
In systems equipped with inverters but without a static bypass switch (STS/UNB) the nominal voltage
value of the inverter “INV nom voltage” (22) is transferred via CAN bus to the inverter units.
In the menu „Main set“, the control process for the battery charge is explained. By the rectifier adjustment
items „Delay Vrec down“ (23) and „Delay Vrec up“ (24) an additional time delay for the control process
„voltage up“/“voltage down“ can be adjusted. At “0” the normal regulation mode is active (1 step per
second).
(4) Battery
27 The nominal capacity (25) provides a
basis for all relative current values (in %)
which are set under the item „Main set“.
To enter is the capacity value of one
battery.
At systems with several batteries the
UPC3 automatically calculates the total
capacity value according to the battery
count.
25
For the evaluation of the battery
unsymmetry the location of the tapped
point has to be advised to the UPC3. The
26 cell count (27) up to the tapped point is
28a counted from –Vbatt. If the difference of
28b the measured and calculated
unsymmetry voltage exceeds the value
of the set „Battery unsymm.” (26), a
failure bit is activated.
VBatt • N tapped
Calculated unsymmetry voltage: VSym = ; N = Cellcount
N total

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ATTENTION! Battery unsymm. (26): At an adjustment of 2V the measured value may differ about
+/- 1V from the calculated unsymmetry voltage value.
The detection of an open battery fuse only is possible if the battery tap is located behind the battery fuse.
If the difference between system- and battery voltage is greater than parameter “Vdiff Fuse case” (28a)
and the battery current less than parameter “Itrigg fuse case” (28b), the flag „Fuse open“ is activated in
the signal matrix.
For the temperature compensation of
the charge voltage the temperature
29 sensor (29) of a battery has to be
activated, e.g. Batt1.
The temperature coefficient (30) and the
basis temperature (31) depend on the
battery and have to be asked at the
manufacturer.
Example:
30 Vload = Vnom + Tk * N cell * ∆t

31 with Tk = -4mV/cK; Ncell=24; ∆t=+5°K
Vload = 54,3V + (−0,004) * 24 * 5

Vload = 53,8V at 30°C
2.4.2 Location specific parameters
(1) Installation
Serial no., location, service no., contact
person, etc. The text has no effect on
the system function!

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(2) Ethernet module

The optional available SNMP agent
(internal communication plug-in board)
for the UPC3 takes over the set ethernet
addresses after each change of the
configuration.
IP, Gateway und Netmask have to be
assigned via the network administrator.
Alarm messages via SNMP (Traps) can be
sent to 5 different receivers.
The entries „Manager“ and „Port#1-#4“
currently are not analysed.
Via „Severity Trap1“ up to “Severity
Trap5“ the alarm levels for the 5 trap
groups can be set up.
(3) UPC3
Logo line 1 and Logo line 2 as well as the

35 version number „release“ (35) (not
changeable) of the UPC3 firmware
appear at the display of the unit in the
main menu.
In the inscription fields „Config. Date“ (36)
and „Config. Person“ (37) automatically
the date and person of the last change
of the configuration are entered
The languages (38) English, German and
Swedish currently are integrated in the
UPC3 firmware.
The baud rate (39) of the serial interface
36 (UPC3 front) has been set to 57600 baud
(default). Changes can be recommended
37 only if the cable is extremely long.
38
A cable length of 5 m is save at 57600
baud. A cable length of 15 m is save at
19200 baud.
39 If the cables are shielded, a doubling or

triplication of the reach is possible.

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2.4.3 Measuring system
(1) Assignment shunt

The parameter group „Assignment Shunt“ just is shown if the configurator is selected in the mode “special
parameter”. In this menu it is possible to assign for each of the measuring values (e.g. battery current) an
user-defined input parameter (e.g. input I1).
Default values: V1 = Battery voltage, V2 = System voltage and V3 = Unsymmetry voltage
I1 = Battery current, I2 = Load current and I3 = General measuring value I3
Temperature sensor T1 for Batt1 and T2 as general measuring value T2
Assignment shunt
The entered value proves that e.g. at a
current flow of 50A a voltage value of
60mV falls at the shunt.
At this point the shunt values of the 3
UPC3 input currents as well as the 6
shunts of the maximum 2 connectable
battery monitoring boards (per board 3
channels) can be entered.

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2.4.4 Thresholds
40 (1) Threshold values

41
All adjustments in this group serve as
42 generation of signal bits.
The exceedance of the limit of the
battery overvoltage „Vmax“ (40) or the
undershooting of the limit of the battery
undervoltage “Vmin” (42) or battery
warning voltage “Vwarn” (41) generate
45a the respective failure bit in the signal
matrix.
For the monitoring of the system voltage
45b
the values Vmax (43) and Vmin. (44) can
be defined too.
43 44
The monitoring of the battery
unsymmetry should be realised as
described in the chapter „Main Set“. The
threshold values „Vtapp“ (45a), (45b) are
suitable only in special uses.
46 „Temperature high“ (46) refers to all
47 temperature sensors.
„Battery Operation“ (47) is visible via a
negative current flow. Due to errors of
48 measurement the threshold should not
amount below 5% of the shunt value.
The measurement of insulation failures „Rinsul error“ (48) is possible only in non earthed systems. The
adjustment should accord with the system voltage, e.g. 48V system 48kΩ Rinsul.
ATTENTION! Exceeds the battery voltage the limit „Vmax“ (40), all rectifiers get the command „OFF“
via CAN bus.
ATTENTION! If the system voltage exceeds the limit „Vmax“ (43) or undershoots the limit „Vmin“
(44), all inverters get the command „OFF“ via CAN bus. In systems with STS/UNB (mains
bypass) the static bypass switch takes over the control of the inverters from the UPC3.
49
(2) Main set
The load current limit „LimLoad current“
(49) which has been set in the group
„Main set“ generates an alarm bit in the
failure matrix if the value is exceeded.

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(3) Thresh. gen. par

For the UPC3 measuring input I3 a
minimum (50a) and a maximum (50b) can
be defined. The exceedance or
50a
undershooting of one of those values
generates an alarm bit in the signal
50b matrix.
Via temperature T2 (51) the temperature
51 e.g. of the cabinet can be
displayed/monitored.
For the general measuring values Gx (52)
following voltages are assigned per
52 default:
G1 = UPC3_V1 (System voltage)
G2 = UPC3_V2 (Battery voltage)
G3 = UPC3_V3 (Tapped voltage)
G4 = UPC3_Vi (Insulation voltage)
2.4.5 Alarm signalling

(1) Digital inputs
60 Under the item „Digital inputs“ the 8

internal (60) and 8 external (61) digital
inputs of the UPC3 can be inverted and
delayed.
The 8 internal inputs (60) (1.1 bis 8.1) are
61
freely available at the UPC3 connection
board.
The 8 external inputs (61) (1.2 bis 8.2)
optionally are available via connection of
an external CAN board (DIG8).
(2) Signals enable

Under the item „Signals enable“, all
62
external and internal failure-/signal bits
can be enabled to an output. Thereby
e.g. relays or SNMP traps can be
63 activated.
A list of the several failure bits is shown
at item 2.6.
64
The list “Error state” (63) is of great
importance. If a signal of the list get
65 active, the red LED (front side UPC3)
starts blinking. Furthermore the list “Error
state” acts as mask for the generation of
66
SNMP traps. Only signals which have
been activated at “Error state” and

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“Modem/Traps” (65) are reported.
In the list „Disable Signals“ (62), several signals can be disabled for all other lists.
All signals which have been activated in the list „Events History“ (64), end up on the history memory of the
UPC3. The history memory contains of maximum 250 messages and stores appeared as well as
disappeared events/failures. The readout and reset takes place directly at the UPC3 unit or via the
configuration software.
The red LED „Alarm“ at the front of the UPC3 blinks at active signals in the error list. The green LED
can
be parameterised via the list „LED Ok“ (66). The error list as well as the list „LED OK“ contain the same
content in the delivery status, but „LED Ok“ is inverted in the group signals switching mode (“Signals Sw
mode”).
Via the signal lists „LED 1 RD“ up to „LED
6 RD“ the functions of the six LEDs of the
optional available UPC3 remote display
are assigned.
The lists “relay 1.1” up to “relay6.1”
switch the internal relays K1 up to K6 of
the UPC3. The contacts are available at
the UPC3 connection board.
With the list “relay 1.2” up to “relay 6.2”
the relays of the optional available relays
board (CAN-RYB) are activated.
(3) Signals switching mode

Under the group „signals Sw mode“ the
set up lists before can be inverted at
their output or can be provided with a
time delay. It is common practice to let a
relay operate at failure free condition so
that a cable break can be recognised as
failure. Due to this fact the relay output
is inverted, e.g. relay 1.1 = 1
If the green LED () shall glow if no
failure occurs, the LED also must be
inverted.

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LVD/PLD function
The three fields for LVD, PLD1 and PLD2 nearly are identical and therefore exemplary shall be explained on
the basis of the LVD function.
The parameter „Source select“ (71)
decides on the general LVD/PLD
72 73 functionality. The selection “0” (OFF)
deactivates the LVD/PLD function.
Selection “1” (V1= system voltage), “2”
71 (V2= battery voltage) or “3” (V3= battery
tapping point) refer “Low limit<OFF” (72)
and “Low limit<ON” (73) to the particular
measuring voltage. Selection “4”
switches the LVD/PLD function
70 depending on battery operation (47) (see
thresholds); the voltage thresholds are
inoperable. Selection „5“ (mains error)
only makes sense in conjunction with the
connection of an external Mains
Monitoring Board (MMB), optional.
72 73
For the control of the LVD/PLD either the
internal/external relays or the LVD/PLD-
71
optocoupler are available (see parameter
“Source select” (70)).
Function LVD/PLD for source V2: The
LVD/PLD contactor switches off, as soon
as the battery voltage falls below the
70 limit „Low limit<OFF“ (72) and the drop
delay has been elapsed. The reactivation
of the contactors takes place if the „Low
limit< ON“ (73) has been exceeded. For
the LVD function directly, for the PLDs as
73 soon as the connect delay has been
72 elapsed.
71
70
Due to the fact that the power load disconnection directly increases the battery voltage, the hysteresis
between the switch-off voltage “Low limit OFF” (72) and the switch-on voltage “Low limit ON” (73) must be
great enough to avoid a direct activation of the contactors.

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2.4.7 Special Functions

(1) Enable
75
In the group „Enable“, special functions
can be activated at the UPC3.
Is a parameter set to „0“, the function is
deactivated. Is a parameter set to “1” or
greater, the function is activated.
A battery test (75) can be
76 started/stopped by different ways at
the UPC3. Possibilities:
77
-Start/stop via front buttons/menu of
the UPC3
- Start via date & time
- Start day to day
- Start/stop via an external command
e.g. SNMP, configuration software
- Start/stop via digital input
Similar to the battery test the boost
charge (77) can be started/stopped by
different ways:
- Start/stop via front buttons/menu.
- Start via undershooting of the start
voltage
- Start after battery operation
- Start after mains failure (optional MMB)
- Start/stop via an external command
e.g. SNMP, configuration software
78 - Start/stop via digital input
- Start after battery test end (BtstE) by
79 declaration of the end criteria
At activating via digital inputs (76)(78)
80 81 for the start element “1” has to be set
and for the stop/inhibit element “2” has
to be set. Possible for it are the internal
82 83
digital inputs 1-8 of the UPC3.
If the parameter „Store Test data“ (79) is activated, the readout of the measuring values for voltage,
current and temperature after a finished battery test is possible.
For the automatic initialising of an internal/external modem the parameter (81) or (82) has to be set to „2“.
„1“ simply activates the modem menu (manual start).
The parameter „OptoC SNMP enabl“ = “1” allows the LVD/PLD rejection via SNMP agent (optional).

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(2) Battery test

84 85 An activated battery test either can be
stopped manually or automatically via
86
exceeding of the terminating criteria.
The automatic terminating criteria „Max
DischargeCap“ (85) (e.g. 80% of the
battery capacity discharged) and „Max
Test-durat.“ (86) (e.g. 240 min battery
operation kept up) stops the battery
test without failure, whereas the
undershooting of the minimum discharge
voltage “MinDischarge vt” (84) stops the
test with a failure.
The reset of the battery failure bit is possible via a restart of the unit; deleting is possible via the buttons
or via a successful battery test.
(3) Store battery test data
The recorded test data during a battery
test are not stored continuously but
depending on the variations of the
measuring values.
The less the parameter value or the greater the variations, the more datasets are stored. The readout of
the datasets takes place via the UPC3 configurator (see „options battery test“).
(4) Boost charge
The general enabling of the boost charge
already has been described under the
item „Enable“. In this menu the
thresholds for the start of an automatic
boost charge has to be entered.
If the battery voltage at activated boost charge exceeds the parameter „FollowUpChgeAbov“, the follow
up charge duration „FollowUpChgeDura“ starts. If the follow up charge duration has been elapsed, the
boost charge is finished.
(5) Counter cells
87
Counter cells in an USV system shall
protect the consumer load against
overvoltage, e.g. during a boost charge.
88 89
First of all the voltage reference (87)
(1=Vbatt; 2=Vtapp; 3=Vload) and
following the ON and OFF threshold is
set.
If the assigned voltage exceeds the ON threshold (88), a signal bit „counter cell 1“ is activated and at
following undershooting of the OFF threshold (89) deactivated.

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(6) MODBUS module

For the internal communication interface
an optional MODBUS module is available.
After each change of the configuration
the MODBUS module automatically
collects the parameters „Slave address“,
„Baud rate“, „Parity“ and „Mode“ from the
UPC3 controller.
(7) Mains monitoring

90 91 In conjunction with an optional available
92 external mains monitoring board (CAN
MMB), the UPC3 is able to detect a mains
failure or phase break down. The
thresholds of Vmin (90) and Vmax (91)
refer to the set default value (see item
“Comb parameter”) of the inverters (22).
If only one special phase should be
monitored, the other phases can be
deactivated via parameter (92).
(8) Modem
93
For remote control, the UPC3 can be
extended via an optional internal or
external modem. The activating of the
modem operation takes place in the
parameter group „Enable“.
For the normal modem operation
(communication with the configurator
software), the „extern_dial-in“ has to be
activated (bit=1). All the rest of the bits
are set to „0“ (default).

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Explanation modem check-bits (93)

Daily report
The modem automatically dials the entered telephone number (97) according to the configured values
„weekday“ and time (94). After a connection has been released the modem disposes an “Okay” string. If
„hold_after_ok“ is set to „0“, the UPC3 afterwards disconnects the modem connection.
Error message
If an error signal occurs in the UPC3 which has been assigned to the output „modem“ (group „signals
enable“), the modem automatically dials the entered telephone number (97) after the time delay has been
elapsed (95). After a connection has been released the modem disposes an “Error” string. If
„hold_after_err“ is set to „0“, the UPC3 afterwards disconnects the modem connection.
Standby dialling (=extern_dial-in)
If „extern_dial-in“ has been activated, it is possible to dial into the system (enter password, see parameter
„password“). “Extern_dial-in” excludes „call-back“.
Call-back
The UPC3 does not answer a phone, but analyses ringing signals. After a third ring the UPC3 recognises
the telephone call and automatically dials the entered telephone number (97). “Call-back“ excludes
“extern_dial-in”.
0/1= pulse/tone
Pulse- or tone dialling
Hold after Ok
See daily report.

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Hold after err

See error message.
Cable_mode
Not available!
Auto_answers
Not available!
No_state_displ
The display of the modem state is hidden from the display. Not recommended!
Via the parameter „RepeatCountTXerr“ (96) is

adjusted how often the UPC3 should try to dial the
94 telephone number (see „Error message“).
Initial.string (98):
AT AT%O AT&F %dATX3E0L1S0=0
This is adjusted in the configuration of the UPC3.
This instruction set is executed from the left to the
right and transferred to the modem. Specific
features are the tokens “%” (e.g. %O, %d). Those are
not transferred but are commands which are
95
executed via the UPC3.
96
A blank and the end of the string effects the
97 transfer of a CR LF (ENTER KEY at PC).
98
99
The Initial.string (see above) works nearly with all standard modems and should be changed only in
exceptional cases. For the AT commands which are understood from your modem please see the
attendant manual. Important! The modem must not answer self acting (ATS0=0), otherwise the pass word
is avoided.
Token (UPC3 commands)
%m Sending without \r\n and waiting for answer from the modem
%d 1 s pause
%p 0.25 s pause
%t40 Timeout 40 s Default 5 s (1-99 s)
%t Timeout 320 ms min = 320 ms
%t0 ditto
%t100 ditto
%t400 Timeout 400 ms 320 .. 999 ms
%O Waiting for OK\r\n modem message
%C Waiting for CONNECT\r\n ditto
%0 Waiting without check Default
%% results in % as normal character
Communication operation of the string AT AT%O AT&F %dATX3E0L1S0=0
(/r/n = carriage return line feed)
Explanation of the AT commands:
AT &F= Factory setting
X3= Do not wait for dial tone
E0= 0 Deactivates echo of sent bytes
L1= Loudspeaker active, sound level 1
S0=0 Modem answers not self acting

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2.4.8 UPC3 Enabling of signalling/text

(1) Text digital inputs
It is possible to assign individual text to
the digital inputs of the UPC3. This text
then also appears in the failure/event list
or in the trap message of the SNMP-
Agent.
Example:
The inputs 6.1 up to 8.1 have been
assigned for the fuse monitoring.
The remaining text groups are parameters exclusive for the indication via the display of the UPC3.
The module identification text “Module ID-texts” is read out via CAN-Bus from the connected devices (e.g.
rectifiers) and can not be parameterised via the UPC3 configurator.
(2) Enable display

Via setting of the parameter to „0“, the
indication can be hidden from the display
of the UPC3.
A hidden indication has no effect on the
system function or on the SNMP agent.
It is not necessary to hide the indication
groups which are not available according
to the system configuration manually. If
e.g. only one battery is connected and
parameterised, only one battery is
indicated in the display.

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2.5 Parameters which only get active via a restart

Changes at following parameters only get active via a restart.
It is a difference whether they are changed in the display or via configurator.
Restart
Parameter Display Configurator Remark
Logo line 2 (parameter yes yes ---
group “UPC3”)
Baud rate UARTe yes yes ---
(parameter group “UPC3”)
Modem internal yes/no yes/no If a modem has been enabled, the
(parameter group (see „Remark“) (see „Remark“) modem is initialised after a restart. A
„Enable“) start is also possible via display (see item
1.8.2.4 “operating status modem”)
Modem external yes/no yes/no ditto
(parameter group (see (see
„Enable“) „Remark“) „Remark“)
Language no yes ---
(parameter group “UPC3”)
2.6 List of failure bits/signal bits of the UPC3

The following list includes all failure/signal bits (failure text) according to the matrix in the parameter
group “Signals enable”
Failure Parameter
no. Description
no. (Alarm ID no.) Failure text
0 Fuse 1 Via Fuse Monitoring Board monitored fuse

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Failure Parameter
no. Description
32 Dig. input 1.1 (60) Internal digital input
40 Dig. input 1.2 (13) (61) External digital input via CAN bus
48 Vbatt<Vmin (B1) (40) Only at battery count > 0

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Failure Parameter
no. Description
55 not used
56 Vbatt>Vmax (B1) (42) Only at battery count > 0
63 not used
64 Vbat<Vwarn (B1) (41) Only at battery count > 0
71 not used
72 Vtapp<Vmin (B1) (45a) Only at battery count > 0
79 not used
80 Vtapp>Vmax (B1) (45b) Only at battery count > 0
87 not used
88 Vload<Vmin (C1) (43) System undervoltage comb1
89 not used
90 not used
91 not used
92 not used
93 not used
94 not used
95 not used

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Failure Parameter
no. Description
96 Vload>Vmax (C1) (44) System overvoltage comb 1
97 not used
98 not used
99 not used
100 not used
101 not used
102 not used
103 not used
104 T>Tmax (Batt1) (46) Only at battery count > 0
111 not used
112 Asymmetrical(B1) (26) (27) Only at battery count > 0
119 not used
120 Fuse open (B1) (28) Only at battery count > 0
127 not used
128 Battery oper(B1) (47) Only at battery count > 0
135 not used
136 Insulation (48) Insulation failure comb 1
137 not used
138 I3 <> Imin/max3 (50) General measuring value ex version 114 build 150
139 T3 <> Tmin/max2 (51) General measuring value ex version 114 build 150
140 G1 <> Gmin/max1 (52) General measuring value ex version 114 build 150

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Failure Parameter
no. Description
144 REC Error (C1) (11) Rectifier failure
145 REC No CAN (C1) (11) Rectifier no CAN receiving
146 REC Redundancy (12) Redundancy failure
147 REC Load (C1) (19) Rectifier load limit
148 REC Load distrib (20) (21) REC count > 1
149 not used
150 not used
151 not used
152 DCC Error (C1)
153 DCC No CAN
154 DCC Redundancy
155 DCC Load
156 DCC load distrib
157 not used
158 not used
159 not used
160 INV Error (C1) Inverter failure
161 INV No CAN (C1) Inverter no CAN receiving
162 INV Redundancy Inverter redundancy failure
163 not used
164 not used
165 not used
166 Lim Load current (49) Load current is greater than adjusted limit, e.g. 80%
167 not used
168 Boost charge (77) Boost charge has been activated
169 Battery test (75) Battery test has been activated
170 Battery test err (80) Battery test stopped with failure „undervoltage”
171 Fan (boost chge) Fan boost charge active
172 Counter cell 1 (88) (89) Counter cell 1 active
173 Counter cell 2 Counter cell 2 active
174 Difference Ah
175 not used
176 Fan Rack: Error Fan rack defective
177 Fan Rack: No CAN Fan rack no CAN receiving
178 SBS: Error state
179 SBS: No CAN
180 MMB: Error state
181 MMB: No CAN
182 BMB: Error state
183 BMB: No CAN
184 not used
185 not used

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Failure Parameter
no. Description
186 DEB: Error state (13)
187 DEB: No CAN (13)
188 not used
189 not used
190 RB: Error state (14)
191 RB: No CAN (14)
192 RD1: Error state
193 RD1: No CAN
194 FMB: Error state
195 FMB: No CAN
196 XXA: Error state General measuring value
197 XXA: No CAN General measuring value
198 XXX: Error state General measuring value
199 XXX: No CAN General measuring value
200 L1: V<> Vmin,max (92) Failure phase 1; via CAN bus via MM board
203 LVD Optocoupler (70) (71) Optocoupler ON = Contactor dropped out
204 PLD1 Optocoupler (70) (71) Optocoupler ON = Contactor dropped out
205 PLD2 Optocoupler (70) (71) Optocoupler ON = Contactor dropped out
206 Tsensor lim Batt (26) (58) Temperature higher than threshold
207 Tsensor Limit (26) Temperature sensor short circuit or cable break
208 Modem1: Login
209 Modem2: Login
210 Modem1: No OK
211 Modem2: No OK
212 Modem1: No CONNECT
213 Modem2: No CONNECT
214 Internal failure 214
226 CAN_ 0 Node state
227 CAN_ 1 Node state
228 SerialE WrongRcv
229 SerialM WrongRcv
230 SerialI WrongRcv

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Failure Parameter
no. Description
231 SerialF WrongRcv
232 CTS SerialE
233 CTS SerialM
234 CTS SerialI
235 CTS SerialF
236 CRC (config)
237 CRC Fatal (conf)
238 PowerOFF (Events)
239 Power Supply 1
240 Power Supply 2
241 Comm Configurator
244 not used
245 not used
248 not used
249 not used
250 not used
251 not used

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2.7 Technical Specifications UPC3 & UPC3S (S= small version)
Type UPC3-24 UPC3-48/60 UPC3-110 UPC3-220

Article code 301-003-498.00 301-003-598.00 301-003-798.00 301-003-898.00
Type (small version) UPC3-24S UPC3-48/60S UPC3-110S UPC3-220S
Article code 301-003-497.00 301-003-597.00 301-003-797.00 301-003-897.00
Supply voltage range 19.2VDC-35VDC 35VDC-75VDC 80VDC-135VDC 185VDC-275VDC
Voltage measuring range 0-100VDC 0-100VDC 0-300VDC 0-300VDC
Current measuring range 0-60mV (shunt value programmable)
Power consumption app. 3W
Voltage measuring inputs 3
Current measuring inputs 1x ±60mV; 2x 0- 60mV
Temperature measuring input 2x (sensor KTY81-220)
Digital inputs 8 (isolated)
LCD display 2x 16 characters; background lighted
LED indications Operation (green); System OK (green); Alarm (red)
6 (isolated; max. 0.5A @ 60VDC); expandable with CAN node DCC-RB6 to max. 12
Relay outputs
relays
Interfaces:
USB interface USB connector
CAN interface Proprietary CAN protocol
3x optocoupler output for control of max. 3pcs. LVD relay or 1pc. LVD and 2pcs.
LVD/PLD–drive
PLD relay
Modem connection Internal analogue modem socket (modem board optional)
SNMP connection Internal SNMP adapter socket (SNMP adapter optional)
Controller functions Desired value for compensation of charge voltage, boost charge voltage, battery
test voltage; boost charge mechanism (power, voltage and time related), LVD
control, PLD control; time controlled battery test; charge current limitation;
dropping diode (counter cell) control (2 stages)
Monitoring functions Entire battery voltage, unsymmetrical battery voltage, battery charge current,
battery operation; isolation fault, battery voltage low, battery voltage high, CAN
bus status, CAN connected module status; external alarm loops
Yes; active fault text message; flash based stack memory of last 250
Event history function
faults/events with time stamp
Battery test memory Yes; storage of last 3 battery test results; storage of the last battery test curve
RTC with time and date Yes
Control buttons 4; UP/DOWN/ENTER/ESC
Main processor 16Bit Fujitsu
Languages German, English, Swedish; other versions loadable on demand
Ambient temperature Operation: -20°C to +55°C; non condensing; Storage: -40°C to +85°C
Cooling Convection cooling
Climatic conditions according to IEC 721-3-3 class 3K3/3Z1/3B1/3C2/3S2/3M2
Max. installation altitude ≤ 1500m
Audible noise <30dBA
Type of construction (small version) ¼ x 19“, 3U (1/6 x 19’’, 3U)
Dimensions (Dimensions small version) 106.3/133/326.5 mm (71/128/280 mm) W/H/D
Weight (Weight small version) approx. 1.8kg (approx. 1.3kg)
Type of enclosure / Protection class IP20 (front panel) / 1

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Colour (front panel) RAL 7035; black imprint

CE conformity yes
Compliance to safety standards EN60950-1; VDE0100 T410; VDE0110; EN50178; EN60146
Compliance to EMC standards EN55011/22 class “B“; EN61000-4 T2-5
Connections 1x DIN41612-M-connector 2x32-pole
2.7.1 Dimensional drawings UPC3 & UPC3S
Drawing: UPC3
Drawing: UPC3S

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UPC3 & UPC3S

Notes to this manual

Eltek Valere Industrial GmbH

 Copyright ELTEK VALERE INDUSTRIAL 2007. All rights reserved.

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

Current revision status of the UPC3 user manual

Revision Description Writer Date

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

Safety Instructions/Waste Disposal Rules .......................................................................................................................6

Universal Power Controller UPC3........................................................................................................................................7

1.1 Technical Description .......................................................................................................................................7

1.2 The Concept .......................................................................................................................................................8

1.3 Measurement inputs...................................................................................................................................... 12

1.4 Quantity of the rectifiers: adding, removing............................................................................................. 13

1.6 Display .............................................................................................................................................................. 14

1.7 Operating elements ....................................................................................................................................... 15

1.8 The menu ......................................................................................................................................................... 16

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.9 Communication Interface ............................................................................................................................. 23

2.1 In General ......................................................................................................................................................... 24

2.3 UPC3 Parameter Groups ............................................................................................................................... 25

2.4 Configuration of the UPC3............................................................................................................................ 28

2.5 Parameters which only get active via a restart....................................................................................... 46

2.6 List of failure bits/signal bits of the UPC3................................................................................................ 46

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

Safety Instructions/Waste Disposal Rules

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.1 Technical Description

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.2 The Concept

1.2.2 Temperature controlled output voltage

In this operation mode, the battery

1.2.3 Charge current limitation

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.2.4 Unregulated output voltage

If the rectifiers do not get a control signal, e.g. because of:

1.2.5 PLD function (Power load disconnect)

1.2.6 LVD function (Low voltage disconnect)

1.2.7 Battery asymmetry

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.2.8 Battery test

1.2.9 Battery test data memory

Additionally the following data of the last battery test is saved:

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.2.10 Boost charge

1.2.11 Monitoring of the power supply capacity utilization

REC load limit set to 50%

Due to this, the load limit of each rectifier is equal to 25A

The UPC3 generates an alarm “REC load” if a higher current is withdrawn.

1.2.12 Monitoring of redundant power supplies

The facility is equipped with 3 rectifiers, 1 unit is configured as redundant:

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.3 Measurement inputs

1.3.1 Voltage measurement inputs

1.3.2 Current measurement inputs

1.3.3 Temperature measurement inputs

1.3.4 Measurement range monitoring

For the battery voltage three thresholds are adjustable:

ELTEK VALERE INDUSTRIAL©2007 UM_UPC3_E_R03

1.4 Quantity of the rectifiers: adding, removing

Attention: Actual alarms only can be deleted by fault repair.

It can be distinguished between two kinds of alarms: