Originally developed for a military vehicle project, the RUG-TC has been used for many surface boat, submarine, rail and other automotive installations over two decades. The standard ruggedised build has 2 × mounting bars underneath the unit to securely fix to the horizontal plain. If rack height is limited then a 2mm mounting plate extending at the rear is optionally possible Each RUG-TC is able to withstand up to 20g of mechanical shock across X, Y and Z axes allowing it to operate across rugged terrains. The PSU operates from temperatures as low as -10°C all the way up to 55°C. Along with excellent performance against shock and vibration the ruggedised TC modules can withstand condensing humidity of up to 95%. 

Each RUG-TC is built into a 19" rackmounting case as standard. Units can be treated to an integration into a flight case or static enclosure. Common options include mains cables, passive indication of any residual DC voltage, isolation monitoring of DC cables and a panel mounted emergency stop. Switch panels with removable DC links can be fitted for modular systems. This simplifies the reconfiguration between series, parallel or independent use. Simple wheeled cabinets are also available.

Up to 64 RUG-TC modules can be arranged in series, parallel or matrix array configurations. Each module is able to operate independently, so that systems can be reconfigured, expanded or broken up as needs dictate. Inbuilt system comms allow users to switch between various set-ups.

The modular approach is useful for companies who regularly need to power different sized devices. Individual modules can be used for energising multiple small devices, then grouped together for larger projects. The diagram shows all the possible combinations with eight 500V modules.

Sense Compensation

Sense plus terminals are built into the RUG-TC for the connection of sense wire which compensates for voltage drops in the load lines. This has a number of advantages over traditional sense. It is permitted to interrupt the load line during operation (voltage on). The maximum voltage drop compensation is adjustable. The voltage difference between RUG-TC output and sensing point is monitored. If a set limit is exceeded, the RUG-TC unit shuts off.  This is particularly useful for applications with long cables often prone to unwanted voltage drops, such as powering downhole tools.

Versatile Limit Setting (VLS)

The VLS allows the RUG-TC's output relays to be activated automatically when specific output values are met, protecting the DUT from any damaging conditions. Output voltage, current and power values which exceed or fall below a given limit or operating window can be programmed to trigger the relays. Active and inactive areas of operation are defined by a limit value, hysteresis value or a directional designator for the hysteresis.

Every module features constant current, constant voltage, constant power as standard. Adjustable internal resistance is also provided, should you need to simulate an energy storage device when powering a DUT.

Power Factor Correction

RUG-TC modules have a Power Factor Correction (PFC) circuit integrated into the input stage as standard. This enhances the overall efficiency of the modules across the output power range when compared to a unit that does not have PFC. The current harmonics of the RUG-TC meet the EN61000-12 regulations for a mains SCE >= 120 value. In practice, this means a significant lower peak current value, a decrease of RMS value of the phase current and less perturbations of other equipment running on the same grid.

The inbuilt PFC is also ideal for operating the power supply from a generator. Generators tend to be sensitive against high current peaks, and their voltage controllers may have some stability problems with non-sinusoidal load currents. The PFC feature forms a lowpass filter and therefore, both the repetitive current peaks and also the harmonic content is enhanced. This will help the generator system maintain a stable and reliable output.

A variety of control methods are available. As standard each module is built with isolated analogue and RS-232 interfaces. Front panel control and display along with IEEE 488.2 (GPIB), USB, RS-422 and Ethernet interfaces are optionally available.

Standard Low Level Protocols

The Low Level Protocols (LLPs) are often ideal for mission critical applications. The LLPs give access to the hexadecimal memory addresses for a given function such as setting and reading of voltage, current and power limit along with switching output on/off.  Second level functionality can also be programmed. This includes adjusting voltage and current slopes and optimising the PID controllers. The user can also program the internal relays for V, I and W. These relays can be used to enable/disable the output depending on user set thresholds or to provide a warning signal. Function sequences, previously stored in the memory, can also be triggered via LLP enabling complex DC waveforms to be implemented.

The LLPs ensures that these power supplies can be used in situation where a Windows or Linux based PC cannot be relied upon. With 5 to 9 Bytes the LLPs provide a protocol with the lowest overheads for high reliability applications where only a PLC may be deemed appropriate.

RS-232 Interface

The RS-232 interface is configured as a Sub-D 9 pin connector (female) and is located on the front panel. This interface can be optionally moved to the rear panel. The graphical user interface, TopControl is operated via RS-232. The software runs on Windows and allows the user to control, measure and configure the power system.

Analogue Interface

The control port is configured as a Sub-D 25 female connector and is located on the rear panel. It allows output values to be set and read proportionally using a 0-10VDC analogue signal. Digital inputs and outputs enable various functions such as the interlock and output ON/OFF. A 10VDC reference is provided for analogue control. Digital functions are switched via a high/low signal. A 24VDC supply voltage is provided for these functions.

CANmp Interface (Option /CANMP)

CANmp is a high speed digital interface operating at 1kHz. The interface gives users the capability to customise the CAN protocol. Up to 50 messages are user configurable. Along with the CAN ID the data length code, byte order, start bit, data type and signal factor can be adjusted by the user. A DBC file is provided and messages can be easily configured within the standard windows software. Messages can be sent cyclically or upon receipt of a sync or syncID signal.

Standard TopControl GUI

All RUG-TC units come with a simple and intuitive TopControl operating GUI as standard. Live values of the power supply are displayed graphically along with any warning and error messages. The software provides a variety of second level parameters, ideal for users who like to optimise their processes. In standard user mode the operator can remotely program set values, enable voltage output as well as the ability to analyse different variables including set and actual values via the integrated scope.

The scope function can simultaneously record up to 8 system variables. Recording can be started manually or by a defined trigger event from any variable of the system. All actual and set values (currents/voltages/power/internal resistance) can be recorded. Other recordable items include system temperatures, intermediate DC circuit, low voltage auxiliary power supplies, error related values and variables from the controller section. 

A password protected section is available to the advanced user and service technician. In addition to the standard functions the authorised user is able to:

• Program linear ramp functions at start up and set value steps during operation
• Configure multi-unit operation
• Program the PID controller parameters
• Program the unit's limit values
• Calibrate and adjust values as necessary
• Update the firmware

Function Generator (Option /TFE)

Complex DC waveforms can be implemented through an optional embedded function generator. The highly programmable nature of the function generator allows users to plot out exact waveforms. This is often advantageous when emulating a power device with a very specific behaviour profile. For example, when providing the DC energy to the coils powering a ship's sonar system, a specific pulse behaviour can be programmed and replicated.

As well as custom shapes, standard square, sawtooth and sine waveforms can be plotted against time. Voltage/current and voltage/power relationships can also be programmed where necessary. Parametric programming is possible, where 
instead of the time axis, an input variable V_IN, I_IN or P_IN can be selected.

Soft Tools

An API for dotNET/C# programming is provided to simplify the integration into 3rd party control and measurements software platforms such as LabVIEW and Matlab. The API can be used to integrate into Python or remote systems based on the REST architecture.

Electric/Battery Drive Cycling (Option /BATCONTROL)

To conduct advanced tests, BatControl software is available. The GUI allows the power systems to implement both preset and user defined charging profiles on battery packs and capacitors. The programmable nature of the GUI also allows a variety of performance issues to be investigated such as lifetime tests, system degradation analysis, as well as shot and burst overload tests.

Battery Emulation (Option /BATSIM)

When testing battery powered equipment, BatSim provides a convenient method for the RUG-TC to emulate the output of different sized battery stacks. Nearly all relevant electrical characteristics are programmable, including the number of cells, energy capacity, cut off limits, chemistry type and nominal voltage.

Capacitor Simulation (Option /CAPSIM)

The output characteristics of a real capacitor stack can be emulated when CapSim is installed with RUG-TC modules. Number of cells in series/parallel, state of charge, cell cut off limits, dynamic capacitance and resistance are programmable.

Solar Array Simulation (Option /SAS)

A solar array simulation GUI is available should users need to accurately test PV inverters in the field. The software has all EN 50530 tests pre-installed. The GUI allows users to edit irradiance, temperature and amplitude values. Previous tests have been conducted using over 400,000 individual data points, with more possible. 

Integrated Safety Relay (Option /ISR)

For additional safety, a mechanical interlock is available for the mains input of the RUG-TC. The integrated safety relay provides shutdown safety according to EN 13849-1 category 2/3. The ISR is connected to the external safety switch loop. If the external loop is opened, the DC-output of the power system is powered down immediately.

Protection Against Output Bars (Option /PACOB)

A specially produced cover is available which provides protection against accidental contact of AC and DC current bars. 

Automatic Voltage Matching with RPP (Option /RPP)

When charging an energy storage device, an external arrangement providing Reverse Polarity Protection (RPP) is recommended for devices without an automatic voltage matching circuit. With the RUG-TC energised but output off, the RPP senses the voltage of the connected energy storage device. A contactor is closed after matching the voltage, to prevent large inrush currents and arcing on start up.

Powering Onboard Transmitters

The RUG-TC can provide the short and precise DC pulses needed to power on-board transmitters in defence vehicles. Military land vehicles require ultra-reliable power supplies for mission critical electrical equipment. Each unit is able to withstand up to 20g of mechanical shock across X, Y and Z axes allowing it to operate across rugged terrains. The PSU operates from temperatures as low as -10°C all the way up to 55°C.

Powering Sonar Systems

The precise nature of sonar systems requires a highly controlled power supply. A poorly regulated PSU may provide too much energy to the sonar system's transducers, which can cause quenching. This is where the water pressure drops so low that it boils, potentially destroying the transducer. The quenching power limit rises with depth due to increased ambient pressure, so the maximum power output needs to be adjusted accordingly.

A PSU a with poor power factor can have a knock on effect on components and cabling sizing. This is particularly an issue for smaller vessels where space is at a premium. Overall system efficiency is reduced, which means more diesel is needed for the generator to power the sonar system.

The RUG-TC provides the controlled DC energy to coils powering a sonar system. The unit's passive power correction ensures an excellent PFC is maintained.

Mobile Battery Charging

The RUG-TC's wide AC input ensures charging is always possible from generators or local grid conditions. A passive Power Factor Correction (PFC) circuit integrated into the input helps a generator maintain a stable and reliable output. 

Should you need to cycle packs or discharge them to a safe level for transit, then a heat dissipative discharge section (DDU) is optionally available. The DDU features a front panel which allows users to adjust the minimum threshold voltage. This automatically stops the discharge once a preset level is reached, preventing a damaging deep discharge of the battery pack, which may happen when using unmonitored resistor banks.

A disconnection of the DDU can also be initiated by error monitoring of the fans or DC disconnectors, temperature monitoring and via the fan controller. Users can connect remotely to the front panel of the discharge unit via an Ethernet interface. Current measurement via the front panel and a discharge counter are also optionally available.

Powering Downhole Tools

Applications with long load lines often suffer from unintended voltage drops, such as downhole tools used in hydrocarbon exploration. The RUG-TC's sense plus allows voltage drops to be compensated for throughout the entire length of a load line. This feature is also ideal for powering subsea devices.