4100+/UT Universal Power Supply

Jumper Placements, Switch

Settings, and Terminations
Cautions and Warnings DO NOT INSTALL ANY SIMPLEX PRODUCT THAT APPEARS
DAMAGED. Upon unpacking your Simplex product, inspect the contents of the
carton for shipping damage. If damage is apparent, immediately file a claim
with the carrier and notify Simplex.
ELECTRICAL HAZARD - Disconnect electrical power when making any
internal adjustments or repairs. Servicing should be performed by qualified
Simplex Representatives.

STATIC HAZARD - Static electricity can damage components. Therefore,

handle as follows:
1. Ground yourself before opening or installing components (use the 553-484
Static Control Kit).
2. Keep uninstalled component wrapped in anti-static material at all times.

Introduction The Universal Power Supply (UPS) consists of two assemblies including a
Switcher Assembly (636-341) and a Communicating Power Supply Controller
Assembly (565-247). Together, these two assemblies form a power supply
which is electrically similar to the Intelligent Power Supply (IPS) previously
installed in 4100-Family systems. The UPS has the following features that differ
from the IPS.

110Ah battery charger.

NICAD battery charger.

External battery charger operation.

For further information concerning the UPS, reference field wiring diagrams
841-731 and 841-995.

In This Publication The following topics are covered in this publication.

Topic See Page #

Overview 2
Jumper Placements 5
DIP Switch Settings 7
Connections and Terminations 9

1998 Simplex Time Recorder Co., Gardner, MA 01441-0001 USA 574-758

All specifications and other information shown were current as of publication, and are subject to change without notice.

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 Overview

Switcher Assembly The switcher assembly is the core of the UPS. Operating from a
120/220/240VAC line, via the four place AC connector (see Figure 1), the
switcher converts the AC line voltage to 28.5VDC for system use. It provides
8A maximum continuous current and 4A of current for battery charger use only.

Communicating Power The Communicating Power Supply Controller Assembly is attached to the front
Supply Controller Assembly of the switcher assembly. With the controller assembly installed, the UPS
provides both 8VDC and 24VDC power and charges system batteries with up to
a 110Ah capacity.

Status Monitoring The UPS monitors and reports the following status information to the 4100-
Family Master Controller using 4100 communications:

AC power loss/brownout

Earth troubles

Low battery

Battery disconnected

Overvoltage/undervoltage conditions

PMSO/PMSI power supply monitor loop

Supply Tap Current

Continued on next page

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 Overview, Continued

Universal Power Supply

Power Harness
Terminations

Switcher Assembly
Power Harness (636-341)

P11 and P12

Power Supply
Controller Assembly
(565-247)

P1,P2, P3, and P5

4 Place AC Connector To P11 and P12

(Located on base of supply)

Note: Product shown exploded for

detailed view Figure 1. Universal Power Supply

Battery Charger The UPS battery charger charges the batteries, runs tests to verify capacity, then
provides short circuit protection for the batteries. The charger can charge
batteries of up to 50Ah capacity using the UPS C-Tap. Batteries with up to
110Ah capacity can be charged if both the B-Tap and the C-Tap are used.

Continued on next page

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 Overview, Continued

Battery Charger (Continued) Every 90 seconds, during normal operation, while the power supply is running on
AC power, the charger tests the charge on the batteries. If the batteries are over
23.2VDC, a normal battery status is sent to the Master Controller. If the batteries
fall below 22.5VDC, a “BATTERY LOW” Trouble is sent to the Master
Controller. If less than 2VDC is read, a “BATTERY DISCONNECTED”
Trouble is sent to the Master Controller, and the charger is turned OFF.
If after 96 hours of continuous charging, the battery charge current has not
dropped below 459mA (with lead-acid batteries), the power supply reports a
“BATTERY CAPACITY” Trouble and the charger turns OFF. This trouble
clears when the batteries become fully charged. The trouble is reported so that
damaged batteries can be replaced.

Specifications The UPS requires 6-inches of bay space in a 4100 cabinet. With up to 50Ah
batteries, the UPS provides 8A at 28.5VDC power (Tap A and Tap B). With
110Ah batteries the UPS provides 4A at 28.5VDC power (Tap A only). Each
option provides 3A at 8VDC for system logic.

Power Harness The power harness connects the switcher to the controller. The RED wire goes
(See Figure 1) to the “+” connection on the switcher. The BLACK wire goes to the “-”
connection on the switcher. The YELLOW wire goes to the “CHG” connection
on the switcher.

Indicator Functions The following indicators are present on the Communicating Supply Controller
Assembly. (See Figure 2.)
LED 1: Power LED.
The green “Power ON” LED indicates normal AC power. When this LED is
ON, it does NOT indicate whether the power supply is on batteries or AC, only
that the state of the AC power is “normal.”
LED 2: Trouble LED.
The yellow “Trouble” LED indicates that normal communications with the
Master Controller are not taking place when the supply is configured as a
communicating supply.

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 Jumper Placements

Jumper Functions
The PROM Configuration Jumpers listed in Table 1 are factory installed and
change only if the PROM type is changed. These jumpers are not field-
selectable.
JW1-7: PROM Configuration Jumpers.
Table 1. PROM Configuration Jumpers (For Reference Only)
PROM INSTALLED REMOVED
27C64 1, 2, 5 3, 4, 6, 7
27C256 1, 3, 4, 5 2, 6, 7
27C512 3, 4, 6, 7 1, 2, 5

POWER HARNESS

See Figure 1 P15

for terminations (“B” TAP)
P16 P17 (“C” TAP)
TB2

P14 (“A” TAP)

P11
P9 P12

P8

PROM
P6
740-801

SW2
SW1

LED 2

LED 1
P1 (“A” TAP RTN) P2 P4
P3 P5
(“B” TAP RTN)
(“C” TAP RTN)
Figure 2. Communicating Power Supply Controller Assembly

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 Jumper Placements, Continued

Jumper Functions (Continued) P6: Battery Disconnect.

This jumper allows the “NO BATTERY” Trouble to be defeated in systems

without batteries.

IMPORTANT: Do not use this jumper to bypass troubles from a

temporarily disconnected battery.

Jumper P6 is configured in the following manner:

Position 1-2: Normal Configuration.

Position 2-3: No Battery Configuration.
P7: Not used.

P10 and P13: Must remain in positions 1-2.

NICAD Battery Charger Adjustment

Position 1-2: Normal operating configuration

Position 2-3: Charger adjustment configuration

Follow Steps 1 through 6 for NICAD batteries only (there are not adjustments
for lead acid batteries).

1. Disconnect the batteries.

2. Set Jumpers P10 and P13 to Position 2-3.
3. Measure the voltage at the battery charge output with respect to 0V.
4. Slowly adjust R143 until the voltage reads 25.5 +/- .1 VDC
5. Set Jumpers P10 and P13 to Position 1-2.
6. Reconnect the batteries.

P16: Earth Detect Jumper.

Jumper P16 enables or disables the Earth Detect feature of the UPS. P16 is
configured in the following manner:

Position 1-2: Earth Detect Enabled (Default).

Position 2-3: Earth Detect Disabled.

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 DIP Swich Settings

Jumper Functions SW1-3 through SW1-6: See Table 2.

SW1-7: This switch configures the battery charger. Position ON enables 50 Ah
battery charging. Position OFF enables 110 Ah battery charging.

Note: With position OFF is selected, the B-Tap is not available for
system power.

SW1-8: Spare.
The eight-position DIP switch SW1 (located on the Communicating Power
Supply Controller Assembly board) identifies the configuration of the power
supply. The various positions of Switch SW1 are described below.
SW1-1: This switch allows retrofit of the IPS. Position ON tells the
supply to act like an IPS in terms of the messages sent to and
received from the 4100-Family Master Controller. Place this
switch in the ON position (default).
SW1-2: This switch is used for audio applications. Position ON indicates
that amplifiers powered by the “B Tap” must switch to battery
when told to do so by the 4100 Master Controller.

WARNING: B-Tap power is removed on AC fail.

Position OFF indicates that amplifiers should switch to battery

when AC is lost.

Power Supply DIP Switch The power supply can operate in the following modes shown in Table 2 below:
Settings
Table 2. SW1-3 through SW1-6 DIP Switch Settings

DIP Switch Position

Configuration Interpretation
3 4 5 6

OFF ON ON ON Power Supply with NICAD Battery

OFF ON ON OFF Power Supply with Lead-Acid Battery
OFF ON OFF ON Power Supply without Battery Charger
Power Supply w/Audio (25W Amp) and
OFF OFF* ON ON NICAD Battery
Power Supply with Audio (25W Amp) and
OFF OFF* ON OFF Lead-Acid Battery
Power Supply with Audio (25W Amp)
OFF OFF* OFF ON without Battery Charger

* Requires proper programming selection (6005) Power Supply and charger

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 DIP Swich Settings, Continued

Address/Baud Rate DIP DIP Switch SW2 has eight-positions that are used to set the power supply
Switch SW2 address and baud rate. The switch is configured in the same manner as the
Address/Baud Rate DIP Switches on the other 4100 daughter cards.

SW2-1: Communications baud rate.

ON: 9600 Baud
OFF: 1200 Baud

SW2-2 through SW2-8: Board address, with the LSB (least significant bit)
of the address being set by SW2-8.

Table 3. Typical Address 1 and 2 Settings for SW2

LSB MSB
Address # 8 7 6 5 4 3 2
Address 1 OFF ON ON ON ON ON ON
Address 2 ON OFF ON ON ON ON ON

Note: The OFF (or open) position of the switch is a logic “1”; the ON
(or closed) position of the switch is a logic “0.”

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 Connections and Terminations

Connections and The following I/O connections and terminations are available on the
Terminations Communicating Supply Controller Assembly. (Refer to Figure 2.)
Table 3. Signal Supervisory Inputs

Connection Description

“A Tap” Signal Supervisory Input. P1 is used to

P1
monitor the “A Tap” Signal Power Harness.
“B Tap” Signal Supervisory Input. P2 is used to
P2
monitor the “B Tap” Signal Power Harness.
“C Tap” Signal Supervisory Input. P3 is used to
P3
monitor the “C Tap” Signal Power Harness.

Note: Default is 733-664 Jumper Plug.

Continued on next page

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 Connections and Terminations, Continued

Connections and Use Tables 4 through 13 for reference purposes.

Terminations (Continued)

Table 4. P4-4100 Communications Interface

Connection Description

P4 is a communications interface with 4100-style

P4 communications for use by the communicating
supply. The following connections are available.
P4-1 Common - Communication 0V.
P4-2 Code - Coding Bus (not used by UPS).
TXD - Transmit data to system. Open collector with
P4-3
620 Ohm output impedance.
P4-4 RXD - Receive data from system. 0 to 28.5VDC input.

Table 5. P5-PMSI Interface

Connection Description

The PMSI interface allows connection to and

control of existing non-intelligent supplies via the
P5
Power Module Supervisory Input. The following
connections are available.
P5-1 24V Common.
Coil - Open drain output sinks current for battery
P5-2 changeover relay coil on expansion power supplies.
Maximum current of 1 Amp.
PMSI - Input; 100K pullup. Monitors power supply
P5-3 loop. Normally pulled low by the electrically furthest
supply in a “daisy chain.”
P5-4 Not used.
P5-5 Not used.
P5-6 Not used.

Continued on next page

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 Connections and Terminations, Continued

Connections and
Terminations (Continued) Table 6. P8-Audio Control Interface

Connection Description

P8 is a ten position ribbon cable connector. The

signals on this connector monitor and control
P8
amplifiers. The following connections are
available:
P8-2, -4, -6,
24V Common.
-8, -10
Music Active - Output, open collector, 150mA
P8-1
maximum.
Amp Reset - Output, open collector, 150mA
P8-3
maximum.
Amp Has Sw to Backup - Input, 15K pullup, normally
P8-5
held low by amplifier.
Amp Trouble - Input, 15K pullup, normally held low by
P8-7
amplifier.
Amp Switch to Battery - Output, open collector, 150mA
P8-9
maximum.

Table 7. P9-Switcher Interface

Connection Description

P9 is an eight position flex cable connector. The

signals on this connector are used to monitor and
P9
control the 565-341 switcher assembly. The
following connections are available:
+24V UPS - Power input, provides power for controller
P9-2, -4
board and 8V converter.
+24V Main A/D - A/D input. Used by A/D to determine
P9-3 the output of the switcher portion of the supply.
Power Loss/Brown Out - Comparator input; 2.2K
P9-6 pullup. Normally high; pulled low by switcher on
power loss or brownout.
Battery Changeover - Output; open collector.
P9-8 Activates relay coil on switcher board when low for
normal AC operation; releases for battery operation.

Continued on next page

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 Connections and Terminations, Continued

Connections and
Terminations (Continued) Table 8. P11-Current Limit Resistor 2

Connection Description

P11 is the connection to the 2 Ohm current-limiting

P11
resistor for the “C” Tap charger output.

Table 9. P12-Current Limit Resistor 1

Connection Description

P12 is the connection to the 2 Ohm current-

P12
limiting resistor for the “B” Tap charger output.

Table 10. P14-“A” Tap/8 Volt Output

Connection Description

P14-1 0V
P14-2 8V Common
P14-3 “A” Tap output
P14-4 8V output

Table 11. P15-“B” Tap Output

Connection Description

P15-1 0V
P15-2 “B” Tap output

Table 12. P17-“C” Tap Output

Connection Description

P17-1 0V (Not Used).

P17-2 “C” Tap output. (Not Used).

Continued on next page

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 Connections and Terminations, Continued

Connections and
Terminations (Continued) Table 13. Terminations

Termination Description
TB1 Option Interface (Not Available).
TB2 Output Connections. Terminal Block TB2
provides extra connection points for the “A”, “B”,
and “C” Taps. Transient suppression is provided
at the block. The following connections are
available on TB2:
TB2-1 0V.
TB2-2 0V.
TB2-3 “C” Tap output (Not Used).
TB2-4 “C” Tap output (Not Used).
TB2-5 0V.
TB2-6 0V.
TB2-7 “B” Tap output.
TB2-8 “B” Tap output.
TB2-9 0V.
TB2-10 0V.
TB2-11 “A” Tap output.
TB2-12 “A” Tap output.

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 574-758
Rev. A
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