Unipower PCM500 Series User manual

PCM500 SERIES
POWER CONTROL & MONITOR SYSTEM
DESCRIPTION
POWER CONTROL & MONITOR SYSTEM
¿OneMountingPosition High:1.75”
¿19- or 23-Inch Rack Mounting
¿Positive or Negative Polarity Plant
¿Reverse Polarity Protected
¿48 or 24VDC Versions
¿Controls & Monitors Up to 16 Rectifiers
¿Centralized Plant FloatVoltage Adjust
¿Centralized Plant Equalize Voltage Adjust Option
¿Battery Temp. Compensation Option
¿Optional Digital Voltmeter and Ammeter Panel
¿8 LED Alarm Indicators
¿8 Form C Relay Contact Alarm Outputs
¿Over & Under Battery Voltage Alarms
¿Battery Voltage & Current Test Points
¿Compatible with Mercury & Vanguard Rectifiers
¿Easy Wire Connections on Rear
¿Alarm Enable on Back Panel
UNIPOWER Telecom’s PCM500 Series
Power Control and Monitor System
(PCMS) is a one mounting position high
(1.75 inches) basic control and monitoring
system for DC power plants. It controls up
to 16 rectifiers in up to 4 shelves, precisely
setting the float voltage and equalize
voltage (optional) on all rectifiers
simultaneously.It monitors the battery
voltage and current by means of front
panel test points or optionally by a front
panel digital voltmeter and ammeter.
A front panel yellow LED indicates that the
controller is in the optional equalize voltage
mode. Front panel red LEDs give the following
alarms: rectifier fail alarm-minor, indicating a
single rectifier failure;rectifier fail alarm-major,
indicating two or more rectifier failures; AC input
failure on any rectifier; failure on any fuse or
circuit breaker; failure on one or both low voltage
disconnects; battery overvoltage; and battery
undervoltage.These alarms all have isolated
Form C relay contact outputs.
The PCM500 is available in either 48 or 24VDC
versions and will operate with a positive or
negative polarity plant. It comes with brackets
that permit mounting in either a 19- or 23-inch
relay rack and can be mounted from the front of
the rack with offsets every quarter-inch from
front to back to align with exisitng rack-mounted
equipment.The front panel has voltage adjust-
ment potentiometers for float voltage, equalize
voltage (option), battery overvoltage and
undervoltage, and temperature compensation
set (option). A front panel switch puts the PCMS
in either float or equalize voltage mode. A front
panel green/red LED indicates the controller is
operating or has failed.The PCMS 500 mates
with UNIPOWER Telecom’s rectifiers and
shelves.
FEATURES
www.unipowertelecom.com
954-346-2442
SAFETY CERTIFICATIONS
LVD73/23/EEC
TWO-YEARWARRANTY
MODEL FUNCTION
PCM500 Basic Power Controller
UL1950
CSA 22.2, No. 950
EN60-950

DIV. OF UNIPOWER CORP. • 3900 Coral Ridge Drive, Coral Springs, Florida 33065, UNITED STATES • Tel: [phone] • Fax: [phone] • [email protected]
UNIPOWER EUROPE • Parkland Business Centre, Chartwell Road, Lancing, BN15 8UE, ENGLAND • Tel: [phone] • Fax: [phone] • [email protected]
SPECIFICATIONS,PCM500
ALL DIMENSIONS IN INCHES (mm).
All specifications subject to change without notice.
INPUTS
Voltage1................................................................... 48VDCor24VDCNominal
Polarity ................................................................... Positive or Negative Plant
MonitoringInputs............................................Low Voltage Disconnects 1 & 2
..................................................... Fuse Alarms 1 through 5
..................................... Battery Voltage & Current Metering
................................................. TemperatureCompensation
......................................................................Battery Sense
..................................................................... Battery Supply
OUTPUTS
Control Outputs ......................................................................... CurrentShare
........................................................................ RemoteAdjust
Alarms, Form C Relay Contacts ............................................. EQA = Equalize
.................. RFA-MIN=RectifierFailure-Minor
................. RFA-MAJ=RectifierFailure-Major
......................................... ACFA=ACFailure
......................... FA = Fuse or Breaker Failure
pcm500-revA-01-08-02.pdf
................... LVDA = Low Voltage Disconnect
........................... OVA = Battery Overvoltage
.......................... UVA = Battery Undervoltage
SAFETYSTANDARDS .................... UL1950,CSA22.2No.950,EN60-950
ENVIRONMENTAL
OperatingTemperature Range .................................................... 0°C to 50°C
StorageTemperature Range................................................... -40°C to +85°C
Humidity ............................................................ 0% to 95%, Non-Condensing
PHYSICALSPECIFICATIONS
CaseMaterial .......................................................................................... Steel
Finish ................................................................................. Powder Coat Gray
Dimensions, Inches (mm) ......................................1.75 H x 19.00 W x 9.00 D
(44.5 x 483 x 229)
Rack Mounting Width ............................................................ 19 or 23 Inches
NOTE: 1. Model must be specified for operating voltage.
FRONTVIEW
CODE VOLTAGE
1 -48V (Pos. Gnd.)
2 +48V(Neg.Gnd.)
3 -24V (Pos. Gnd.)
4 +24V(Neg.Gnd.)
Model No.: PCM500 - - - - -
CODE OPTION
EV EQUALIZE
VOLTAGE MODE
MP METERPANEL
TC* BATTERYTEMP.
COMPENSATION
25 25A
30 30A
50 50A
75 75A
100 100A
150 150A
200 200A
250 250A
300 300A
500 500A
1000 1000A
1500 1500A
2000 2000A
J1-J4 SIGNAL CONNECTORS
PIN FUNCTION
1 RemoteEnable
2 ThermalAlarm-1
3 CurrentMonitor-1
4 ThermalAlarm-2
5 CurrentMonitor-2
6 ThermalAlarm-3
7 CurrentMonitor-3
8 ThermalAlarm-4
9 CurrentMonitor-4
10 CurrentShare
11 + Sense
12 RemoteAdjust-2
13 RemoteAdjust-4
PIN FUNCTION
14 ACGood-1
15 DCGood-1
16 ACGood-2
17 DCGood-2
18 ACGood-3
19 DCGood-3
20 ACGood-4
21 DCGood-4
22 SignalCommon
23 -Sense
24 RemoteAdjust-1
25 RemoteAdjust-3
NOTE: J1-J4 Connectors are for rectifier shelves 1-4
respectively. Numbers following functions refer to
rectifier modules 1-4 in each shelf.
J1-J4
CONTROL & MONITORING INPUT &
OUTPUT
LV Disconnect 1 Current Metering
LV Disconnect 2 Temp. Comp. Input
Fuse Alarm 1 Battery Supply
Fuse Alarm 2 Battery Sense
Fuse Alarm 3 Current Share Output
Fuse Alarm 4 Remote Adjust Output
Fuse Alarm 5
FORM C RELAY CONTACT ALARM
OUTPUTS
Equalize Fuse or Breaker
Failure
Rectifier Failure-MinorLow Voltage Disconnect
Rectifier Failure-MajorBattery Overvoltage
NOTE: The ammeter requires an
external 50mV shunt with the
current rating shown in the table.
The shunt code must be specified
as a suffix for the MP Option.
AMMETER
SHUNT RATING
CODE
*This option includes a temperature
probe with 20 foot cable. For longer
cable, contact factory.
➤
➤
1.75 (44.5)
19.00
(483)
➤
➤
REARVIEW
RECTIFIER SHELF CONNECTORS ALARM-ENABLE
DIP SWITCHES TB1 CONNECTOR
50mV Shunt

PRICE: $25.00
OPERATING MANUAL
UNIPOWER TELECOM POWER
CONTROL & MONITOR SYSTEM
PCM500 SERIES
www.unipowertelecom.com
Manual No. PCM-800-3 © 2002 UNIPOWER Corp.
All Rights Reserved
UNIPOWER Telecom, Division of UNIPOWER Corporation
01/14/02 PCM500-Man
NORTHAMERICA •3900 Coral RidgeDrive, CoralSprings, Florida 33065,USA •Tel: [phone]• Fax:[phone] •[email protected]
EUROPE•Parkland Business Centre, ChartwellRoad,Lancing BN158UE, ENGLAND •Tel: [phone]•Fax:[phone] •[email protected]

CONTENTS
SECTION TOPIC PAGE
1.0 Introduction 1
2.0 FeaturesandOptions 1
3.0 SafetyWarnings 3
4.0 Warranty 3
5.0 UnpackingandInspection 4
6.0 Specifications 4
7.0 SafetyandIndustry Standards 5
8.0 Front PanelDescription 5
9.0 BackPanelDescription 6
10.0 LEDIndicators 6
11.0 FrontPanelAdjustmentPotentiometers 6
12.0 DescriptionofOperation 7
13.0 Connections 7
14.0 AlarmEnabling 11
15.0 VoltageandCurrentMeasurements 12
16.0 BatteryTemperatureCompensation 14
17.0 InstallationandSetup 15
18.0 FinalInstallationandConnections 16
Appendix DataSheet

ILLUSTRATIONS
FIGURE TITLE PAGE
1 PCM500Power Control & MonitoringSystem 2
2 FrontandBack Panels of PCM500 2
3 PCM500Functions 8
4 CurrentMeasurement Connections 13
5 Test SetupforSetting BatteryOvervoltageand Undervoltage 13

1
PCM500 SERIES
OPERATING MANUAL
1.0 INTRODUCTION
1.1 ThisOperatingManual should bereadthroughcarefully beforeinstallingand
operatingthePCM500Series.
1.2 ThePCM500 isabasic controlandmonitoring systemforDC powerplants.
Itcontrols upto 16 rectifiersin upto 4shelves, precisely settingthe float
voltageandequalizevoltage(optional)onallrectifierssimultaneously.It
monitorsthebattery voltage andcurrentbymeans offrontpaneltest points
oroptionallybya front paneldigitalvoltmeterandammeter.SeeFigure 1.
1.3 FrontpanelLEDs indicatestatusandalarm conditionsofthemonitored
functions.Frontpanelpotentiometers permit easyadjustmentofthevarious
controlvoltages.FormC relaysalsoindicatestatusand alarms.
1.4 ThePCM500is onlyonemounting positionhigh(1.75inches) tominimize
rackspaceand comeswithbrackets thatpermitmountingin eithera19- or
23-inchrelay rack.It can bemounted fromthe frontof the rackwith offsets
everyquarter-inchfrom front tobacktoalign withexistingrack-mounted
equipment.
1.5 ThePCM500 canbeordered configuredforeither 24or48VDC, either
positiveornegativeplant.Itis reversepolarity protected.
2.0 FEATURES AND OPTIONS
2.1 Features
uLowProfile: One MountingPositionHigh: (1.75Inches)
u19-or 23-inchRackMounting
u48or 24VDCVersions
uPositiveorNegativePolarityPlant
uReversePolarityProtected
uControls& MonitorsUp to16 Rectifiersin Up to4 Shelves
uCentralizedPlantFloatVoltageAdjust
uEightLED Alarm Indicators
uEightForm C RelayContactAlarm Outputs
uOver&UnderBattery Voltage Alarms
UNIPOWER TELECOM POWER CONTROL & MONITOR SYSTEM
PCM500 SERIES

2
PCM500 SERIES
OPERATING MANUAL
Figure 1. PCM500 Power Control & Monitoring System
Figure 2. Front and Back Panels of PCM500
FRONT VIEW
REAR VIEW
RECTIFIER SHELF CONNECTORS ALARM-ENABLE
DIP SWITCHES TB1 CONNECTOR

3
PCM500 SERIES
OPERATING MANUAL
uCompatiblewith All UNIPOWERTelecom Rectifiers
uEasyWireConnections onRear
uAlarmEnableSwitcheson BackPanel
2.2 Options
uCentralizedPlantEqualizeVoltageAdjust
uBatteryTemperatureCompensation(withTemp.Probe)
uMeterPanel(Voltmeter &Ammeter)
3.0 SAFETY WARNINGS
3.1 ThisControlandMonitorSystemoperates atvoltages thatcouldpotentially
behazardous.Furthermore,inadvertant short circuitingofthesystembattery
and/orrectifierby misconnectionorother errorcouldbeharmful. Thisprod-
uctshouldbe handled, testedandinstalledonly byqualifiedtechnicalper-
sonswhoare trainedinthe useofpowersystems andarewell awareofthe
hazardsinvolved.
3.2 Whenoperating thePCM500the chassisgroundterminal mustbecon-
nectedtothe systemframegroundor otherpropersafetyground forthe
protectionofpersonnel.
3.3 Allconnectionsto thePCM500should becarefullycheckedfor errorsbefore
applyingpowertoit.
3.4 Thisequipment isintendedonly forinstallationin a“RESTRICTEDACCESS
LOCATION”.
4.0 WARRANTY
All products of UNIPOWER Telecom, a division of UNIPOWER Corporation, are warranted for
two (2) years from date of shipment against defects in material and workmanship. This warranty
does not extend to products which have been opened, altered or repaired by persons other than
persons authorized by the manufacturer or to products which become defective due to acts of
God, negligence or the failure of customer to fully follow instructions with respect to installation,
application or maintenance. This warranty is extended directly by the manufacturer to the buyer
and is the sole warranty applicable. EXCEPT FOR THE FOREGOING EXPRESS WARRANTY,
THE MANUFACTURER MAKES NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT
NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICU-
LAR PURPOSE. As the sole and exclusive remedy under this warranty, the manufacturer, at its
option, may repair or replace the non-conforming product or issue credit, provided the
manufacturer’s inspection establishes the existence of a defect. To exercise this remedy, the
buyer must contact the manufacturer’s Customer Service Department to obtain a Return Material
Authorization number and shipping instructions. Products returned without prior authorization
will be returned to buyer. All products returned for repair must be shipped freight prepaid to
UNIPOWER. If the buyer fails to fully comply with the foregoing, the buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost
sales, injury to person or property or any other incidental or consequential losses) shall be
available to the buyer.

4
PCM500 SERIES
OPERATING MANUAL
5.0 UNPACKING AND INSPECTION
5.1 Thispowercontrol and monitoringsystemwascarefully tested,inspectedand
packagedfor shipmentfromour factory. Uponreceipt ofthe unititshould be
carefullyunpackedandinspected foranydamageinshipment.
5.2 Ifthere isevidenceof damage,donot attempttoinstall theunit. Thefreight
carriershould be notifiedimmediatelyand aclaimfor thecostof thePCM500
shouldbe filedwiththe carrierfordirect reimbursement. Besureto include
themodeland serial numberofthedamaged unitinallcorrespondence with
thefreightcarrier. Also savetheshipping carton andpackingmaterial as
evidenceofdamage for thefreightcarrier’sinspection.
5.3 UNIPOWERTelecomwill cooperatefullyincase ofanyshipping damage
investigation.
5.4 Alwayssavethe packingmaterialsfor lateruseinshipping theunit. Never
shiptherectifier systemwithoutproperpacking.
6.0 SPECIFICATIONS
INPUTS
Voltage1.................................................. 48VDCor24VDCNominal
Polarity ................................................... PositiveorNegativePlant
MonitoringInputs .................................... LowVoltageDisconnects1&2
.................................... FuseAlarms1through 5
.................................... BatteryVoltage&CurrentMetering2
.................................... TemperatureCompensation
.................................... BatterySense
.................................... BatterySupply
OUTPUTS
ControlOutputs ...................................... CurrentShare
....................................... RemoteAdjust
Alarms,FormCRelayContacts .............. EQA=Equalize
.............. RFA-MIN=RectifierFailure-Minor
.............. RFA-MAJ=RectifierFailure-Major
.............. ACFA= ACFailure
.............. FA=FuseorBreakerFailure
.............. LVDA=LowVoltageDisconnect
.............. OVA=BatteryOvervoltage
.............. UVA=BatteryUndervoltage
SAFETYSTANDARDS................ UL1950,CSA22.2No.950,EN60-950

5
PCM500 SERIES
OPERATING MANUAL
ENVIRONMENTAL
OperatingTemperatureRange................ 0°C to 50°C
StorageTemperatureRange ................... -40°Cto+85°C
Humidity ....................................... 0%to95%,Non-Condensing
PHYSICALSPECIFICATIONS
CaseMaterial............................................. Steel
Finish ..................................................... PowderCoatGray
Dimensions,Inches(mm) ....................... 1.75 H x 19.00 W x 9.00 D
(44.5 x 483 x 229)
RackMounting Width ............................. 19 or 23 Inches
NOTES: 1.Modelmustbespecifiedforoperatingvoltage.
2.Ammeterrequiresanexternalshunt.
7.0 SAFETY AND INDUSTRY STANDARDS
7.1 ThePCM500Control and MonitorSystemmeetsthe followingsafety
certifications:
STANDARD AGENCY
UL1950 UL
CSA22.2-950 CUL
EN60-950 DEMKO
7.2 ThePCM500 is CEmarkedto indicateconformanceto theEuropeanUnion’s
LowVoltageDirective.
8.0 FRONT PANEL DESCRIPTION
8.1 Ontheleft sideofthe frontpanelarethe digitalvoltmeterand digitalammeter.
Thesemetersform theoptionMPand readbatteryvoltageand current.The
ammeterrequiresan external50mVshunt.See Figure2andSection 15.3.
8.2 Atthe centerofthe panelisa green/redLEDalarm whichis normally green
but turnsred uponfailureof thePCM500 ControlandMonitor System.
8.3 Onthe right sidearefour terminalsforreading amperesandvolts, thebattery
currentandvoltage,usingexternalmeters.
8.4 Next,inorder, arethevoltage adjustmentpotentiometersVFL,OV, UV, TC
andVEQ,whose functionsareexplainedin Section11.0.
8.5 Nextis the EQ/FLswitchfor switchingtherectifiers betweenequalizeand

6
PCM500 SERIES
OPERATING MANUAL
floatvoltages.
8.6 Finally, inorder, arethe LEDindicators: RFA-MIN, RFA-MAJ,ACFA, FA,
LVDA, OVA andUVAwhich areexplained inSection10.0.
9.0 BACK PANEL DESCRIPTION
9.1 Fromthe leftside arethe fourrectifier connectors J1through J4which con-
trolandmonitor therectifiershelves andindividualrectifiers.J1 goesto
rectifiershelf no. 1,J2 toshelf no. 2.,etc. SeeFigure 2.
9.2 Inthe centerofthe backpanel arethe24 DIPswitches which enablethe
alarmsforeach rectifier,fuseorbreakerpanel, andlowvoltagedisconnect.
Belowthe switches isthechassis groundterminal.
9.3 Onthe rightside isthe TB1connector with 48terminals forconnecting two-
wirealarminputs, alarmoutputsandother input/outputconnections.These
terminalsaccept AWGnos.14 to22 wiresizes.
10.0 LED INDICATORS
10.1 Yellow LED. Indicatescontroller isintheequalizevoltage mode (option),
determinedbythefrontpanelEqualize/Float switch.
10.2 Red LEDs.Theseare failurealarmsindicatingthe following:
uRectifierFailureAlarm-Minor (asinglerectifierfailure)
uRectifierFailureAlarm-Major(twoormorerectifierfailures)
uACInputFailure(onanyrectifier)
uFailureonany FuseorCircuitBreakerinadistributionpanel
uFailureononeorbothLow VoltageDisconnects
uBatteryOvervoltage
uBatteryUndervoltage
11.0 FRONT PANEL ADJUSTMENT POTENTIOMETERS
Therearefivefrontpaneladjustment potentiometers:
uVFL: FloatVoltage set(12 turns)
uOV: Battery Overvoltageset(singleturn)
uUV: BatteryUndervoltage set(singleturn)
uTC: TemperatureCompensationset (singleturn)
uVEQ: EqualizeVoltage set(single turn)

7
PCM500 SERIES
OPERATING MANUAL
NotethatTemperatureCompensationandEqualizeVoltageareoptionsthat
mustbeordered.
12.0 DESCRIPTION OF OPERATION
12.1 SeeFigure 3.ThePCM500 controlsandmonitors uptofour rectifiershelves
containingup tofourrectifiers each.This isaccomplishedby meansof the
fourconnectors J1throughJ4 whichconnectto rectifiershelvesone through
four,respectively. Throughtheseconnections the PCM500controlsthe
rectifieroutputvoltage whichispresetby theVFL(floatvoltage) andoption-
allybyVEQ(equalizevoltage)adjustment potentiometers.The frontpanel
EQ/FLswitch putstherectifier outputsineither theequalizeor floatmode.
12.2 ThePCM500 alsomonitors theAC inputand DC outputof eachof the
rectifiers andgivesan LEDwarning andFormC relaycontact alarm incase
offailureof anyone.
12.3 ThePCM500also monitorsforalarms uptotwolow voltagedisconnect
panelsand uptofive fusepanelsor circuitbreakerpanels. Thealarm outputs
areForm Crelaycontacts whichcanbe usedforremote orlocal system
alarms.ThePCM500 hasinputsfrom thelow-voltagedisconnectpanels and
thefusepanels orcircuitbreaker panels.
12.4 Otheralarmoutputsareforbatteryovervoltageandbatteryundervoltage.
Thesearealso FormCrelay contacts.
12.5 Batteryvoltageandcurrent arealsomonitoredbythe PCM500.Theyareread
eitherbythe optional frontpanelvoltmeterand ammeterorfromthe front
paneltestpoints. Anexternalshunt isrequiredforcurrent measurement.
13.0 CONNECTIONS
13.1 Rectifier Connections. SeeFigure 2.Rectifierconnectionsare madetothe
J1throughJ4 receptacles,standard25-pin subminiatureDconnectors
(PositronicNo. SD25F0S500XwithFC7520D pins).The matingplugis a
PositronicSD25M0000Zwith MC7520Dpins.Theseconnectors areidentical
toandautomatically matewiththoseon allUNIPOWERTelecomrectifier
shelves:Mercury(RMF), Magellan(RMM,RMP),Vanguard(RVN)and
Ranger(RRS).The tablefollowinggives theconnectionsbypin numberto
therectifiershelves andrectifiers.

8
PCM500 SERIES
OPERATING MANUAL
Figure 3. PCM500 Functions
FUSE/CIRCUIT
BREAKERPANELS
RECTIFIER
SHELVES

9
PCM500 SERIES
OPERATING MANUAL
13.2 Alarm and Other Input/Output Connections. SeeFigure 2. Thesecon-
nectionsaremade toTB1which isa48-pinEuro-style terminalblock.There
aresevenalarm inputs (14terminals),eightForm Crelaycontactalarm
outputs(24terminals) and10terminalconnections forotherinput/output
(I/O)connections.These connectionsarespecifiedin thetablesfollowing.
Inputsonterminals 1-7and42-48are fromrelaycontactson lowvoltage
disconnectpanelsandfuse/breaker panels.An“open”atthese terminals
indicatesanalarm.
ALARMOUTPUTS
TERM
FUNCTION NO.
EQA (NC) 13
EQA (C) 14
EQA (NO) 15
OVA (NO) 16
OVA (C) 17
OVA (NC) 18
RFA-MIN (NO) 19
RFA-MIN (C) 20
RFA-MIN (NC) 21
LVDA (NO) 22
LVDA (C) 23
LVDA (NC) 24
TB1TERMINALCONNECTIONS
NOTE: J1-J4 Connectors are for rectifier shelves
1-4 respectively. Numbers following functions
refer to rectifier modules 1-4 in each shelf.
NC=No connection.
14
25
13 1
J1-J4
J1-J4SIGNALCONNECTORS
PIN FUNCTION
1 NC
2 NC
3 NC
4 NC
5 NC
6 NC
7 NC
8 NC
9 NC
10 Current Share
11 + Sense
12 Remote Adjust-2
13 Remote Adjust-4
PIN FUNCTION
14 AC Good-1
15 DC Good-1
16 AC Good-2
17 DC Good-2
18 AC Good-3
19 DC Good-3
20 AC Good-4
21 DC Good-4
22 Signal Common
23 -Sense
24 Remote Adjust-1
25 Remote Adjust-3
OTHERI/O
TERM
FUNCTION NOS.
I+ (IN) 41
I- (IN) 8
TC (IN) 9 & 40
B+ (IN) 10
B- (IN) 11
CS (OUT) 12
BS+ (IN) 39
BS- (IN) 38
RA (OUT) 37
FUNCTION TERM
NOS.
LVDA1 IN 1 & 48
LVDA2 IN 2 & 47
FA1 IN 3 & 46
FA2 IN 4 & 45
FA3 IN 5 & 44
FA4 IN 6 & 43
FA5 IN 7 & 42
ALARMINPUTS TERM
FUNCTION NO.
FA (NC) 25
FA (C) 26
FA (NO) 27
ACFA (NC) 28
ACFA (C) 29
ACFA (NO) 30
RFA-MAJ (NC) 31
RFA-MAJ (C) 32
RFA-MAJ (NO) 33
UVA (NC) 34
UVA (C) 35
UVA (NO) 36

10
PCM500 SERIES
OPERATING MANUAL
Outputson terminals13-36are FormCrelay contactalarmsfor thefunctions
given.“NormallyClosed” (NC)meansa“short” betweenthisterminaland the
Common(C)terminal when thefunctionisoperating properlywithpower
applied.“NormallyOpen” (NO) meansan“open”between thisterminaland
theCommon(C) terminalwhenthefunction isoperatingproperlywith power
applied.
13.3 Abbreviations/Acronyms. Theseareused intheprevious tables andare
definedinthefollowing table.
13.4 Explanation of Other I/O Connections. Mostof theconnections toTB1 are
alarminputsand outputs.The“Other I/O”connectionsarevarious analog
typeconnections.
13.41 I+ and I- Input. Theseare the+ and- connectionsfrom ameter shunt
thatis used tomeasurebattery current.SeeSection 15.3on
“Current”for further details.
13.42 TC Input. This is theoptionaltemperature compensationinputfrom
thetemperaturecompensationprobe thatcomeswiththisoption. The
probeisused tomeasurebatterytemperature whichisusedto control
theoutputof therectifier.See Section16.0on“Battery Temperature
Compensation”.Thereis no polarityreferenceonthis.
13.43 B+ and B- Input. Theseconnections areto the commonrectifier
outputbus whichisused toprovidepower tooperatethe PCM500
ACRONYM DESCRIPTION
LVDA Low Voltage Disconnect Alarm
FA Fuse/Circuit Breaker Alarm
I+, I- Meter Shunt
TC Temperature Compensation (from probe)
B+, B- Battery (from rectifier bus)
CS Current Share (to rectifier shelves)
EQA Equalize Alarm
OVA Battery Overvoltage Alarm
RFA-MIN Rectifier Failure Alarm - Minor (single rectifier failure)
ACFA AC Failure Alarm
RFA-MAJ Rectifier Failure Alarm - Major (two or more
rectifier failures)
UVA Battery Undervoltage Alarm
RA Remote Adjust (to rectifier shelves)
BS+, BS- Battery Sense

11
PCM500 SERIES
OPERATING MANUAL
circuitry.
13.44 CS Output. This isthe currentshareconnection tothe fourrectifier
shelvesandis usedonlyifadditional rectifiershelvesareadded tothe
system.
13.45 BS+ and BS- Inputs. Theseare batterysenseinputs toPCM500and
areconnectedto thecommonrectifierbus nearthebatterybut onthe
rectifierside ofanybattery disconnectorLVDcircuit.
14.0 ALARMENABLING
14.1 Alarm-Enable Switches. Theseswitchesare locatedatthe centerofthe
backpanel.As shownfollowingthere arefourcolumnswith sixeachDIP
switches.Thecolumns androwsarenumbered.
Eachswitch controlsoneof thealarmfunctions. ThePCM500comes withall
alarmfunctionsdisabled, withtheswitches intheleftposition. Movinga
switchtothe rightenablesthat function.
14.2 Alarm Functions. There are24separatealarmfunctions controlledbythe
Alarm-Enableswitches.Only those functionsusedshouldbe enabled;other-
wisefalse alarms willbecreated. Thefirst16 functionsarerectifier/alarms.
Provisionis madeforshelf numberandrectifier numberforup tofour shelves
withup tofour rectifierseach. SRstands for shelf/rectifier. Asshown inthe
followingtable the shelfno.and rectifierno.correspond totheswitch no.and
positionno., respectively.Thus switchno.2, postionno.3 (2,3)enablesthe
shelfno. 2,rectifierno. 3alarm (SR23).Whenthe properrectifier alarm-
enableswitches are set,ifany onerectifierfails theRFA-MIN (Rectifier
Failure-Minor)red LED willcomeon, andtheRFA-MINForm Crelaywill
changestate. If morethanone rectifierfailsthe RFA-MAJ(Rectifier Failure-
Major)red LED willcomeon andtheRFA-MAJFormC relaywillchange
state.
SWITCHNO.
POSITIONNO.

12
PCM500 SERIES
OPERATING MANUAL
TheFA1 throughFA5alarmsfunction forup tofive fuseor circuit breaker
distributionpanels. Ifanyfuse orcircuitbreaker onanypanel opens,this will
causethe FA (FuseorCircuit BreakerAlarm) redLED to comeon andthe
FAForm Crelayto changestate.The LVDA1and LVDA2alarm-enable
switchesare for oneortwo LowVoltage Disconnectpanels.If eitheroneof
theseexperiencea disconnect, theLVDA (LowVoltageDisconnectAlarm)
redLED willcomeon andthe LVDAForm Crelaywill changestate.
15.0 VOLTAGE AND CURRENT MEASUREMENTS
15.1 Meters and Test Points. Themeterpanel option(Option MP)providesa
digitalvoltmeterandammeter ontheleftfrontpanel tomonitorthebattery
voltageandcurrent.
15.2 Voltage. Thedigital voltmeterreadsbatteryvoltagedirectly,to tenthsofavolt.
The“volts” test pointsonthe rightfrontpanel alsopermitdirect external
measurementofthebattery voltagewhentheMPoption isnottaken.
15.3 Current. Thedigitalammeter isscaledat thefactorytoread amperesbased
ona50 millivolt externalshuntand correspondinginternalscalefactor which
mustbechosen atthetime ofordering.Thefollowing tablegivesthe amme-
tershunt ratingandordering suffixcodefor thecorrect metersettingat the
factory. Theexternalshunt must be connected with correct polarity
acrossthe I+andI- inputterminals (TB1terminals41 and8, respectively).
SeeFigure 4 andSection13.2.
ALARM-ENABLE DIP SWITCHES
POS. SW. NO.1 SW. NO.2 SW. NO.3 SW. NO.4
NO. FUNCTION FUNCTION FUNCTION FUNCTION
1 SR11 SR21 SR31 SR41
2 SR12 SR22 SR32 SR42
3 SR13 SR23 SR33 SR43
4 SR14 SR24 SR34 SR44
5 FA1 FA3 FA5 LVDA1
6 FA2 FA4 NC LVDA2
External 50mV Shunt
AMMETER
SHUNT RATING
CODE
250 250A
300 300A
500 500A
1000 1000A
1500 1500A
2000 2000A
25 25A
30 30A
50 50A
75 75A
100 100A
150 150A
200 200A
AMMETER
SHUNT RATING
CODE

13
PCM500 SERIES
OPERATING MANUAL
Figure 5. Test Setup for Setting Battery Overvoltage and Undervoltage
Figure 4. Current Measurement Connections

14
PCM500 SERIES
OPERATING MANUAL
Thistable showsthat, for example,a 50mV, 100Ashunt isthe shuntresis-
tancethat produces50mV for a100A full-scalecurrent. Inthis case the
shuntresistance is50mV ÷ 100,or 0.5milliohm. Theshunt rating isalways
thefull-scale currentthatproduces 50mVacrossthe shunt.
The3 ½ digitammeterresolves currentreadingsto 0.1Aoverthe 25Ato
200Afull-scale range. From250Ato 2000Afullscale, themeterresolves
currenttothenearestampere.Overall accuracyis moderate,generallywithin
±5%.Current may alsobemeasured atthe“AMPS” testpointsby usinga
50mVfull scale voltmeter.The externalshuntmust bealsoused forthis
measurement.Theactualcurrent mustthenbedeterminedby multiplyingthe
meterreading in millivoltsbythe fullscaleshunt currentdividedby 50.
16.0 BATTERY TEMPERATURE COMPENSATION
16.1 Thetemperaturecompensationoption (Option TC)comeswithatemperature
probeand 20-footcable.The probeisa thermistorwhichis connectedto TB1
pins9 and40. There isno polarityfor thisconnection. The probeis usedto
monitorthetemperatureof the batteryandadjusttherectifieroutput voltage
accordingly.Asbatterytemperature increases,rectifier outputvoltagede-
creases.
16.2 Thechangein output voltagewithtemperatureis -3mV/ºCperbatterycell,
centeredat25ºC. Forexample,fora +10ºCtemperaturechangefrom 25ºC
withthe rectifier charginga48V battery,the changeinthe rectifieroutput
voltagewouldbe:
48
2
rV = 24 cells x 10ºC change x (-3mV) = -720mV = -0.72V
16.3 Theprobecan belocatedin severalpossibleplaces:right onthebattery to
detectthebatterytemperature; nearthebatteryinfree airtodetectthelocal
ambienttemperature;oron thepowerplantmetalframe nearthebattery.For
theprocedureoncalibratingthistemperature compensationsystem, see
Section17.6.
16.4 Ifthe TC probeiseither openedorshorted, therectifieroutputs reverttothe
floatvoltage.
= 24 cells