Samlexpower SEC-1223BBM Le manuel du propriétaire
- Taper
- Le manuel du propriétaire
Switch Mode
DC Power
Supply
with Battery
Backup
SEC-1223BBM
Please read this
manual BEFORE
installing unit
Owner's
Manual
2 | SAMLEX AMERICA INC.
OWNER'S MANUAL | Index
SECTION 1
Safety Instructions ................................................................. 3
SECTION 2
Layout, Output Connection & Dimensions .......................... 7
SECTION 3
Description & Principle of Operation .................................... 8
SECTION 4
Protections ........................................................................ 14
SECTION 5
Installation ........................................................................ 16
SECTION 6
Operation ........................................................................ 21
SECTION 7
Limiting Electro-Magnetic Interference (EMI) ...................... 24
SECTION 8
Troubleshooting Guide ....................................................... 27
SECTION 9
Specications ..................................................................... 30
SECTION 10
Warranty ........................................................................ 32
Disclaimer of Liability
UNLESS SPECIFICALLY AGREED TO IN WRITING, SAMLEX AMERICA INC.:
1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION
PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT,
INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF
ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK.
Samlex America reserves the right to revise this document and to periodically make changes to the content
hereof without obligation or organization of such revisions or changes.
Copyright Notice/Notice of Copyright
Copyright © 2018 by Samlex America Inc. All rights reserved. Permission to copy, distribute and/or modify this
document is prohibited without express written permission by Samlex America Inc.
2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3
SECTION 1 | Safety Instructions
1.1 IMPORTANT SAFETY INSTRUCTIONS
This manual contains important Safety and Operating Instructions. Please read before
using this unit.
1.2 SAFETY SYMBOLS
The following safety symbols will be used in this manual to highlight safety
and information:
WARNING!
Indicates possibility of physical harm to the user in case of non-compliance.
MISE EN GARDE!
L’utilisateur pourrait se blesser lorsque les consignes de sécurité ne sont pas
suivies.
!
CAUTION!
Indicates possibility of damage to the equipment in case of non-compliance.
!
ATTENTION!
Il y a un risque d’endommager l’équipement lorsque l’utilisateur ne suit
pasles instructions.
1.3 INSTRUCTIONS
Please read these instructions before installing or operating the unit to prevent personal
injury or damage to the unit.
!
WARNINGS!
a) DO NOT OPEN TO REDUCE RISK OF FIRE OR ELECTRIC SHOCK. THERE ARE NO USER
SERVICEABLE PARTS INSIDE—REFER TO QUALIFIED SERVICE PERSONNEL.
b) The unit should be grounded to reduce the risk of electric shock. It comes with a
detachable power cord that has a 3 prong, grounded male plug (NEMA5-15P). The
round prong of the plug gets connected to the chassis of the unit. When the power
cord is plugged into the corresponding 3 slot female receptacle (NEMA5-15R), the
chassis of the unit is automatically connected to the Earth Ground through the
Equipment Grounding Conductor that is connected to the round slot of the fe-
male NEMA5-15R receptacle. The power cord must be plugged into a NEMA5-15R
outlet that is properly installed and grounded in accordance with all local codes and
ordinances. Never alter the power cord that has been provided. If the plug of the
cord will not t the outlet, have a proper outlet installed by a qualied electrician.
Improper connection can result in risk of electric shock.
4 | SAMLEX AMERICA INC.
SECTION 1 | Safety Instructions
c) It is recommended that you return your power supply to a qualied dealer for any
service or repair. Incorrect assembly may result in electric shock or re.
d) To reduce the risk of electric shock, unplug the power supply from the outlet before
attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
e) To reduce risk of damage to electric plug and cord, pull by plug rather than cord
when disconnecting the unit.
f) An extension cord should not be used unless absolutely necessary. If an extension
cord is used, make sure that it has 3-prong, grounded male plug (NEMA5-15P) and
3-prong, grounded female receptacle (NEMA5-15R). The size of the current carrying
conductors should be such that they are able to carry at least 10A for the length of
the extension.
g) Place the unit in an area that will allow air to ow freely around the unit. DO NOT
block or obstruct vent openings on the sides and at the bottom or install the unit in
an enclosed compartment.
h) Keep the unit away from moisture and water.
i) NEVER OPERATE TWO OR MORE UNITS IN PARALLEL.
j) Precautions when working with batteries.
- Batteries contain very corrosive diluted Sulphuric Acid as electrolyte. Precautions
should be taken to prevent contact with skin, eyes or clothing.
- Batteries generate Hydrogen and Oxygen during charging resulting in evolution
of explosive gas mixture. Care should be taken to ventilate the battery area and
follow the battery manufacturer’s recommendations.
- NEVER smoke or allow a spark or ame near the batteries.
- Use caution to reduce the risk of dropping a metal tool on the battery. It could
spark or short circuit the battery or other electrical parts and could cause an
explosion.
- Remove metal items like rings, bracelets and watches when working with bat-
teries. The batteries can produce a short circuit current high enough to weld a
ring or the like to metal and thus cause a severe burn.
- If you need to remove a battery, always remove the Negative Ground Terminal
from the battery rst. Make sure that all the accessories are off so that you do
not cause a spark.
MISE EN GARDE!
a) N’OUVREZ PAS DE RÉDUIRE LES RISQUES D’INCENDIE OU DE CHOC ÉLECTRIQUE.
Il N’Y A AUCUNE PIÈCE RÉPARABLE PAR L’UTILISATEUR, REPORTEZ-VOUS À UN
PERSONNEL QUALIFIÉ.
b) L’appareil doit être mis à la terre pour réduire le risque de choc électrique.
Il est livré avec un cordon d’alimentation amovible qui a un 3 broches, prise
mâle (NEMA5-15P). La terre de la che ronde est reliée au châssis de l’unité.
4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
Lorsque le cordon d’alimentation est branché dans la fente correspondante 3
clip femelle (NEMA5-15R), le châssis de l’unité est automatiquement connecté à
la terre à travers le conducteur qui est connecté à l’emplacement de la femme
ronde NEMA5-15R. Le cordon d’alimentation doit être branché sur une prise
NEMA5-15R qui est correctement installée et mise à la terre conformément
à tous les codes et règlements locaux. Ne modiez jamais le cordon
d’alimentation qui a été fournie. Si la che du cordon ne s’adapte pas la prise,
faites installer une prise adéquate par un électricien qualié. Une connexion
incorrecte peut entraîner un risque de choc électrique.
c) Il est recommandé que votre déclaration votre bloc d’alimentation à un
revendeur qualié pour tout service ou réparation. Un montage incorrect peut
entraîner un choc électrique ou un incendie.
d) Pour réduire le risque de choc électrique, débranchez le cordon d’alimentation de
la prise secteur avant l’entretien ou le nettoyage. Commandes de désactivation
ne permettra pas de réduire ce risque.
e) Pour réduire les risques de dommages à la che électrique et un cordon
d’alimentation, tirez par che et non sur le cordon lorsque la déconnexion de
l’unité.
f) Une rallonge électrique ne doit pas être utilisé à moins qu’absolument
nécessaire. Si une rallonge est utilisée, assurez-vous qu’il a 3 broches, prise
mâle (NEMA5-15P) et 3 broches femelle, mis à la terre (NEMA5-15R). La taille
de l’actuel conducteurs sous tension doivent être tels qu’ils sont capables de
transporter au moins 10A pour la durée de la prorogation.
g) Placer l’appareil dans une zone qui permettra à l’air de circuler librement
autour de l’unité. N’obstruez pas les ouvertures de ventilation ou de l’entraver
sur les côtés et en bas ou installer l’unité dans un compartiment fermé.
h) Garder l’appareil à l’abri de l’humidité et l’eau.
i) NE JAMAIS FAIRE FONCTIONNER DEUX OU PLUSIEURS UNITÉS EN PARALLÈLE.
j) Précautions lors de l’utilisation des piles.
- Les batteries contiennent de très corrosif de l’acide sulfurique dilué comme
électrolyte. Des précautions doivent être prises pour éviter tout contact avec
la peau, les yeux ou les vêtements.
- Générer de l’hydrogène des batteries et de l’oxygène au cours de la charge
résultant de l’évolution du mélange de gaz explosifs. Il faut prendre soin de
bien aérer la zone de la batterie et de suivre les recommandations du fabricant.
- NE JAMAIS fumer ou permettre qu’une étincelle ou une amme à proximité
des batteries.
- Procédez avec précaution pour réduire le risque de chute d’un outil
métallique sur la batterie. Il pourrait déclencher ou court-circuit de la batterie
ou d’autres pièces électriques et pourraient provoquer une explosion.
SECTION 1 | Safety Instructions
6 | SAMLEX AMERICA INC.
- Retirer les objets métalliques tels que bagues, bracelets et montres lors de
travaux avec des batteries. Les piles peuvent produire un courant de court-
circuit sufsamment haut pour souder un anneau ou similaires à metal et
donc provoquer des brûlures sévères.
- Si vous avez besoin de retirer la batterie, retirez toujours la borne de masse
négatif de la batterie en premier. S’assurer que tous les accessoires sont off
an de ne pas provoquer une étincelle.
!
CAUTIONS!
a) Please refer to Fig 2.1. Please ensure that the battery is connected with
correct polarity - Positive of the battery to the “Battery +” terminal (6, Fig
2.1) and the Negative of the battery to the “Battery -” terminal (5, Fig 2.1).
Reversal of polarity will blow external Fuse F1. Reversal of polarity may
result in permanent damage to the unit and to the load. DAMAGE DUE TO
REVERSE POLARITY IS NOT COVERED UNDER WARRANTY.
b) Protect the unit against AC line input transients. Use Transient Suppressor in
line with the AC input.
!
ATTENTION!
a) Veuillez vous référer à la gure 2.1 à la page 5. Veuillez vous assurer que
la batterie est connectée avec la polarité correcte - Positif de la batterie
à la borne “Battery +” (6, Fig 2.1) et le négatif de la batterie à la borne
“Battery -” (5, Fig 2.1). Inversion de polarité externe fera sauter le fusible
F1. Inversion de polarité peut causer des dommages permanents à l’unité
et à la charge. LES DOMMAGES DUS À L’INVERSION DE POLARITÉ N’EST
PAS COUVERT PAR LA GARANTIE.
b) Protéger l’appareil contre les transitoires de ligne. Utiliser suppresseur de
transitoire conformément à l’entrée CA.
SECTION 1 | Safety Instructions
6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
2.1 LAYOUT
BOTTOM VIEW
SEC-1223BBM
F1
F2
12V BATTERY 12V DC LOAD
BOTTOM VIEW
SEC-1223BBM
F1
F2
12V BATTERY 12V DC LOAD
BOTTOM VIEW
SEC-1223BBM
F1
F2
12V BATTERY 12V DC LOAD
Fig. 2.1 Layout and Output Connections
LEGEND
1. Lighted Power ON /OFF Rocker Switch (Lights Red when ON)
2. AC Power Cord Inlet – Type “IEC 60320-C14” (Detachable Power Cord with
“IEC 60320-C13” connector on one end and NEMA5-15P Plug on the other end
is provided with the unit)
3. Black Negative (-) DC Load Terminal
4. Red Positive (+) DC Load Terminal
5. Black Negative (-) Battery Terminal
6. Red Positive (+) Battery Terminal
7. Vent opening for cooling fan discharge (Bottom of the unit)
F1. Fast blow Fuse: 32V, 25A
F2. Fast blow Fuse: 32V, 25A
*NOTE 1: 5/64” Hex Key and 2 spare set screws have been provided.
Tubular hole Dia 5 mm/0.2” and set screw
(5/64” Hex Socket Head, #10, 24 TPI,
5/16” long)
*
See NOTE 1
SECTION 2 | Layout & Dimensions
8 | SAMLEX AMERICA INC.
SECTION 2 | Layout & Dimensions
2.2 DIMENSIONS
TOP VIEW
SEC-1223BBM
7.7
13.5
2.5
2.5
223
240.5
61
180
185
53.3
4
Fig 2.2 Dimensional Drawing
SECTION 3 | Description & Principle of Operation
3.1 DESCRIPTION
SEC-1223BBM is a Switch Mode Power Supply (SMPS), which converts 120 VAC, 50/60
Hz (or 230 VAC, 50/60 Hz*) to regulated 14.0 VDC at 23A continuous. It has additional
provision for battery backup with charging in conjunction with external 12V Lead Acid
Battery. The battery is oat charged to 13.5 ± 0.2V (when fully charged).
*NOTE: The unit is factory preset to operate from input voltage of 120 VAC, 50/60
Hz. This may be set to operate from input voltage of 230 VAC, 50/60 Hz by changing
internal setting described at Section 3.1.1 below (Caution! UL listing will not be valid
for 230 VAC input option):
3.1.1 Operation from AC input Voltage of 230 VAC
The unit has been preset to operate from input voltage of 120 VAC, 50/60 Hz. The unit
can be set to operate from input voltage of 230 VAC, 50/60 Hz by changing the position
of the internal jumper. The procedure for conversion to input voltage of 230 VAC, 50/60
Hz is as follows: (Caution! UL listing will not be valid for 230 VAC input option).
8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
SECTION 3 | Description & Principle of Operation
- Switch OFF the unit and unplug the power cord from the AC outlet
- Remove top cover
- For 120 VAC operation (pre-set condition), points “C” and “E” on the printed
circuit board (PCB) have been connected (shorted) with a Yellow colored exible
wire jumper. To convert to 230 VAC input, disconnect the quick disconnect
connector at point “C” by pulling it upwards. Tape this end with an insulation
tape and use a cable to tie it securely to the wire harness running above.
- The fuse on the AC side for the preset input voltage of 120 VAC is rated at
250V, 6.3A (Littel Fuse 21806.3). For 230 VAC operation, use fuse rated at 250V,
4A (Littel Fuse 0218004).
3.2 FEATURES
• Advanced Switch Mode Technology
• Reliable, 12V DC Uninterruptible Power Source (DC UPS) in conjunction with external
12V Lead Acid Battery backup
• Under battery backup function, short time overload of up to 50A for < 1 sec can be
supplied to allow starting of devices that require higher starting surge current.
• High efciency, compact and portable
• Protected against short circuit, overload, over voltage and over temperature
• Cooling by temperature controlled fan improves efciency and prolongs life of the fan
• UL safety listed as “Information Technology Equipment Power Supply” for USA (UL
Standard ANSI/UL-60950-1) and for Canada (CSA Standard CAN/CSA-C22.2 No. 60950-1)
• Complies with FCC Part 15(B), Class B for limits on conducted and radiated
Electromagnetic Interference (EMI)
3.3 PRINCIPLE OF OPERATION
Fig 3.1 Schematic Diagram - Battery Charging / Backup
SMPS
SECTION
L
N
AC Input
V
f
= 0.2 VDC
13.8 VDC
R1=1.2Ω
R2=1.2Ω
14 VDC
D1
D2
D3
3 4 5 6
F2
F1
BACKUP
BATTERY
12V LOAD
BATTERY CHARGING AND
BACKUP SECTION
Please refer to the schematic diagram at Fig 3.1.
The unit consists of 2 Sections:
a) High efciency Switched Mode Power Supply (SMPS) Section (See details at Section 3.3.1)
b) Battery Charging and Backup Section (See details at Section 3.3.2)
10 | SAMLEX AMERICA INC.
SECTION 3 | Description & Principle of Operation
3.3.1 High Efciency Switched Mode Power Supply (SMPS) Section
Refer to Fig 3.1
This Section is a high efciency SMPS that converts 120 VAC, 50/60 Hz (or, 230 VAC, 50/60
with internal jumper setting) to regulated DC voltage of 14.0V. It uses Switched Mode
controller with Pulse Width Modulation (PWM) Control.
3.3.2 Battery Charging and Backup Section
Refer to Fig 3.1
3.3.2.1 In battery charging and backup application, the SMPS Section (details at Section
3.3.1 above) will supply the load current as well as the battery charging current to keep
the battery charged to Float Voltage of 13.5V± 0.2V as long as AC input to the SMPS
is available and the SMPS is working normally. If the AC input to the SMPS Section
fails or if the SMPS Section itself fails, the battery will act as backup power source and
instantaneously supply power to the load.
3.3.2.2 Regulated 14.0VDC from the SMPS Section (details at Section 3.3.1 above) is fed
to the Battery Charging / Backup Section through Schottky Diode “D1” that provides
isolation between the SMPS Section and the battery to prevent the battery from feeding
back into the SMPS Section. When current passes through a diode, there will be a non-
linear Forward Voltage Drop (Vf) across it. As the power dissipated across the diode will
be equal to Forward Voltage Drop (Vf) multiplied by the diode current, it is desirable
that the Forward Voltage Drop (Vf) has a lower value to reduce power dissipation and
hence, improve efciency. Therefore, “Schottky” type of diode has been used that has
lower Forward Voltage Drop (Vf) of 0.4A at 23A. Schottky Diode “D1” has a non linear
Forward Voltage Drop (Vf) as follows:
TABLE 3.1 FORWARD VOLTAGE DROP (VF) AND VOLTAGE AT CATHODE OF
SCHOTTKY DIODE “D1” (FIG 3.1)
(Column 1)
Diode “D1”
current = 0A
(Column 2)
Diode “D1”
current =0.1 to 5A
(Column 3)
Diode “D1” Current
= 19 to 23 A
(Column 4)
Forward Voltage Drop
(Vf) for Diode “D1”
0V 0.25V 0.4V
Voltage at Cathode
of Diode “D1”
(14.0V – Vf)
14V 13.75V 13.6V
It will be seen from Table 3.1 above that the Forward Voltage Drop (Vf) of Schottky
Diodes “D1” ” varies from 0V at 0A (no load) to 0.4V at 23A. Hence, the voltage at the
Cathode of Schottky Diode “D1” will be = 14.0VDC – Forward Voltage Drop across “D1”
and will range from 14.0 V to 13.6V (or say 13.8 ± 0.2V).
3.3.2.3 14.0V to 13.6V (or say 13.8 ± 0.2V) from the Cathode of Schottky Diode “D1” is
fed to 2 branches as follows:
10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11
a) Branch 1 for DC Load: To the Positive Load Terminal (4, Fig 3.1) directly
b) Branch 2 for Battery Charging and Backup: To the Battery Positive Terminal (6
in Fig 3.1) through 2 x 1.2 Ohm parallel connected resistances R1 and R2 (2 x 1.2
Ohm parallel connected resistances will present effective series resistance of 1.2
Ohm ÷ 2= 0.6 Ohm). The battery charging current will be determined by the
following approximate equation:
Charging
Current
= [Voltage at Cathode of Diode “D1” – Voltage at the Battery Terminals] ÷ 0.6 Ohm …Equation 1
3.3.2.4 Using Equation 1 above, it will be seen that the effective series resistance of
0.6 Ohm will limit the charging current. The charging current will be higher when the
battery is more discharged and will progressively reduce as the battery voltage rises
when charged. The rated charging current of 4A is based on the unit supplying 19A to
load and at the same time, charging a typical 100 Ampere Hour (Ah) battery discharged
to 11.1V (70% discharged at Discharge Rate of 23A i.e. at around 5 Hr Discharge Rate of
C/5). When the battery is charged to Float Voltage of 13.5V± 0.2V, the charging current
will reduce to a very low value of around 0.1% of its Ampere Hour (Ah) capacity to
compensate for its self discharge. For example, assuming that 100Ah capacity battery
is being used, the Float Charging Current will be 0.1% of 100Ah or, 0.1A. Therefore,
applying Equation 1 at Section 3.3.2.3 above, the voltage at the Battery Terminals
(5, 6 in Fig and 3.1) will be as given in Tables 3.2.1 and 3.2.2 below:
TABLE 3.2.1 CHARGING VOLTAGE AT BATTERY TERMINALS – LOAD CURRENT 0A
Column (1)
• Load Current = 0A
• Float Charging Current = 0.1A
• Total SMPS Current = 0.1A
Column (2)
• Load Current = 0A
• Full Charging Current = 4.0A
• Total SMPS Current = 4.1A
Column (3)
Voltage at Battery
Terminals based
on Equation 1
(Section 3.3.2.3)
13.75V * – (0.1A x 0.6 Ohm) =
13.69V
*Based on Table 3.1, Column (3)
13.75V * – (4.0A x 0.6 Ohm) =
11.35V
*Based on Table 3.1, Column (3)
TABLE 3.2.2 CHARGING VOLTAGE AT BATTERY TERMINALS – LOAD CURRENT 19A
Column (1)
• Load Current = 19A
• Charging Current = 4.0A
• Total SMPS Current = 23A
Column (2)
• Load Current = 19A
• Charging Current = 0.1A
• Total SMPS Current = 19.1A
Column (3)
Voltage at Battery
Terminals based
on Equation 1
(Section 3.3.2.3)
13.6V** – (4.0A x 0.6 Ohm) =
11.2V
**Based on Table 3.1, Column (4)
13.6V** – (0.1A x 0.6 Ohm) =
13.54V
**Based on Table 3.1, Column (4)
SECTION 3 | Description & Principle of Operation
12 | SAMLEX AMERICA INC.
3.3.2.5 When the AC input to the SMPS Section fails or if the SMPS itself fails, the
battery will provide backup power to the load instantaneously through Schottky Diode
“D2”. Please note that current from the battery to the load will NOT pass through
Resistors R1 and R2 because Schottky Diode “D2” will bypass these resistors due to its
lower resistance.
3.3.2.5.1 Current ow through Schottky Diode “D2” will produce non-liner Forward
Voltage Drop (Vf) as given in Table 3.3 below:
TABLE 3.3 FORWARD VOLTAGE DROP (VF) OF SCHOTTKY DIODES “D2”
(Column 1)
Diode “D2” Current
= 0A
(Column 2)
Diode “D2” Current
= 0.1A
(Column 3)
Diode “D2” Current
= 19 to 23A
(Column 4)
Forward Voltage
Drop (Vf) for Diode
“D2”
0V 0.25V 0.4V
Voltage at Cathode
of Diode “D2”
Battery Voltage – 0V Battery Voltage – 0.25V Battery Voltage – 0.4V
3.3.2.6.1 The voltage available at the Load Terminals (3,4 in Figs 2.1 and 3.1) during
battery backup will be as per Equation 2 below:
Voltage at Load Ter-
minals when battery is
supplying the load
=
Battery Voltage – Forward
Voltage Drop across
Schottky Diode “D2”
...Equation 2
3.3.2.6.2 Examples of voltages at the Battery Terminals (5, 6 in Fig 3.1) at different
states of charge / discharge are given at Table 3.4 below:
TABLE 3.4 VOLTAGE AT BATTERY TERMINALS WHEN AC INPUT POWER HAS FAILED
AND THE BATTERY IS SUPPLYING THE LOAD
Column (1)
• Load current = 19A
• Battery voltage at Floating
Voltage of 13.55V
Column (2)
• Load current = 19A
• Battery voltage of say 11.4V
at 80% discharged state based
on 100Ah capacity discharging
at 5 Hr Discharge Rate of C/5
Column (3)
Voltage at battery
terminals (5, 6
in Fig 3.1) when
AC input power
has failed and
the battery is
supplying the load
[Based Equation 2
(Section 3.3.2.6.1)]
13.54V* – 0.4**V = 13.14V
*Based on Table 3.2.2, Column (3)
** Based on Table 3.3, Column (4)
11.4V – 0.4*V = 11.0V
* Based on Table 3.3, Column (4)
SECTION 3 | Description & Principle of Operation
12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13
3.3.3 Output Voltage Adjustment at No Load
The no load output voltage is factory preset at 14.0V (13.8VDC ± 0.2V) at both the Load
and Battery Terminals. Potentiometer marked “VR1” is provided in the SMPS Circuit
Board for no load output voltage adjustment range of 10.8 VDC to 16.2 VDC.
3.3.4 Normal Power Supply Function when Battery Backup is not used
If battery backup function is not used (external backup battery is not connected), the
unit will work as a normal power supply with ability to supply 23A continuous at 13.8 ±
0.2 V at the Load Terminals (3, 4 in Figs 3.1 and 2.1).
3.4 COOLING AND OVER TEMPERATURE PROTECTION
The unit is cooled by convection and in addition, has a temperature-controlled fan
located at the bottom for forced air-cooling. Two Normally Closed Thermal Switches are
mounted on the windings of the Switching Power Transformer – one for fan control and
the other for over temperature shut down. When the temperature of the transformer
windings rises to ≥ 60°C ± 5°C / 140°F ± 9°F, Thermal Switch for fan control will open
and will activate fan switching circuit to switch ON the fan. When the transformer
windings cool down to ≤ 40°C ± 5°C / 104°F ± 9°F, the switch will close and de-activate
fan switching circuit to switch OFF the fan.
NOTE: The fan may not switch ON at all in case of low loads or in colder ambient
temperatures because the temperature of the transformer windings may not rise to
threshold of ≥ 60°C ± 5°C / 140°F ± 9°F under these conditions.
In case the fan fails or if the cooling is not adequate due to higher ambient temperature,
inadequate air circulation or blockage of ventilation openings, the temperature of the
transformer windings will rise. At temperature ≥ 105°C ± 5°C / 221°F ± 9°F, Thermal Switch for
over temperature shut down will open and will activate over-temperature protection circuit
to shut down the Power Supply Section. When the windings cool down to temperature ≤ 75°C
± 5°C / 167°F ± 9°F, the switch will close, shut down circuit will be de-activated and the output
power from the Power Supply Section will be restored automatically. During the time the
Power Supply Section is shut down due to over temperature, the backup battery will supply
the load and will start discharging. When the Power Supply Section cools down and resets, it
will once again start supplying the load and re-charge the battery.
!
CAUTION!
The fan draws cool air from the vent openings on the sides of the unit and
discharges hot air through vent openings at the bottom of the unit. PLEASE
ENSURE THAT THESE VENT OPENINGS ARE NOT OBSTRUCTED.
!
ATTENTION!
Le ventilateur aspire l’air froid de l’ouvertures de ventilation sur les côtés
de l’unité et les rejets d’air chaud par les ouvertures d’aération au bas de
l’unité. VEUILLEZ VOUS ASSURER QUE CES OUVERTURES DE VENTILATION
NE SONT PAS OBSTRUÉES.
SECTION 3 | Description & Principle of Operation
14 | SAMLEX AMERICA INC.
SECTION 4 | Protections
4.1 OVER LOAD / SHORT CIRCUIT CURRENT PROTECTIONS
4.1.1 Battery Backup Function is not Used - External Battery is not Connected
and the Unit is Used as a Power Supply
In this case, the entire load current will be supplied by the Power Supply Section and will
be limited to a maximum of 25A by its Current Limit Circuitry. If the load tries to draw
a higher current than the current limit value of 25A, the output voltage at the Load
Terminals (3, 4 in Fig 2.1) and the Battery Terminals (5, 6 in Fig 2.1) will not be regulated
and will drop below 13.8V± 0.2V. If the load impedance is further reduced, the current will
remain limited at 25A but the voltage will drop further. In case of short circuit, maximum
limited current of 25A will continue to be supplied into the short circuit but the voltage
will drop to < 2V in case of a near dead short (Load impedance will be very low – say
< 100 milli Ohm). If over-load / short-circuit current of 25A continues over prolonged
period (> 100 sec), the external 25A load side Fuse (F2, in Fig 2.1) will blow and will
disconnect the load. If the overload / short circuit is removed before the external 25A
load side Fuse (F2, in Fig 2.1) blows, the output voltage at the Load / Battery Terminals
will automatically recover when the load current drops to less than 25A.
4.1.2 Battery Backup Function is Used - External Battery is Connected
If the load tries to draw current higher than the current limit value of 25A of the Power
Supply Section, the output voltage of the Power Supply Section will not be regulated and the
voltage at the Load Terminals (3, 4, Fig 2.1) will drop. Portion of overload current beyond 25A
will now be fed from the battery and the battery will start draining at this differential current.
For example, if the overload current was 40A, the Power Supply Section will provide 25A and
the battery will provide the balance 15A. The battery will start draining at 15A. The voltage
at the Battery Terminals (5, 6, Fig 2.1) will start dropping and will be equal to the voltage
corresponding to its actual State of Charge. The voltage at the Load Terminals (3, 4 in Fig 2.1)
will be up to 0.4 VDC below the voltage at the Battery Terminals (5, 6 in Fig 2.1) because of
forward voltage drop across diode D2 (Fig 3.2). This drop will depend on the current being
supplied through this diode (TABLE 3.3). External 25A Fuse (F2, Fig 2.1) on the load side will
blow only on sustained current ≥ 25A for > 100 sec but will not blow at higher short duration
surge currents determined by its Time Current characteristics. For example, based on the Time
Current Characteristics of 32V, 25A fuse Type ATC-25 from Cooper Bussmann, the fuse can pass
extremely high currents for shorter durations is as follows:
• 550A for 10 ms
• 170A for 100 ms
• 40A for 1 sec
• 25A continuous (for > 100 sec)
In case of short circuit on the load side, the external 25A Fuse (F2) on the load side will
blow because of very high additional current supplied by the battery (Additional battery
current supplied into the short circuit on the load side = Short circuit current - 25A from
the Power Supply Section). For example, if a short circuit current of 170A tries to ow
for > 100 ms, 25A will be supplied by the Power Supply Section and the balance 145A
will be supplied by the battery. As the external 25A Fuse (F2, Fig 2.1) on the load side
will see 170A and the external 25A Fuse (F1, Fig 2.1) on the battery side will see 145A,
the external 25A load side Fuse (F2, Fig 2.1) will blow rst.
14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15
SECTION 4 | Protections
4.2 PROTECTION AGAINST REVERSE POLARITY OF BATTERY CONNECTION
In case of reverse polarity of battery connection, internal Diode connected across the
battery output terminals (D3, Fig 3.1) will be forward biased and the external 32V, 25A
battery side Fuse (F1, Fig 2.1) will blow.
!
CAUTION!
Reversal of polarity may result in permanent damage to the unit and to the load.
DAMAGE DUE TO REVERSE POLARITY IS NOT COVERED UNDER WARRANTY.
!
ATTENTION!
Inversion de polarité peut causer des dommages permanents à l’unité et
à la charge. LES DOMMAGES DUS À L’INVERSION DE POLARITÉ N’EST PAS
COUVERT PAR LA GARANTIE.
4.3 OVER TEMPERATURE PROTECTION
!
CAUTION!
Keep the unit in a well-ventilated, cool and open area. DO NOT block the vent
holes on the sides or the discharge openings of the cooling fan at the bottom
of the unit.
!
ATTENTION!
La placer dans un endroit bien aéré, frais et ouvert. N’obstruez pas les orices
de ventilation sur les côtés ou les ouvertures de décharge du ventilateur de
refroidissement au bas de l’unité.
In case the fan fails or if cooling is not adequate due to higher ambient temperature
or inadequate air circulation or blockage of air ventilation openings, the temperature
of the output power transformer windings will rise and at temperature ≥ 105°C ± 5°C
/ 221°F ± 9°F, Thermal Switch mounted on the windings will open and will activate
over-temperature protection circuit to shut down the Power Supply Section. When the
windings cool down to temperature ≤ 75°C ± 5°C / 167°F ± 9°F, the Switch will close, shut
down circuit will be de-activated and the Power Supply Section will be reset automati-
cally. During the time the Power Supply Section is shut down due to over temperature,
the backup battery will supply the load and will start discharging. When the Power
Supply Section cools down and resets, it will once again start supplying the load and
re-charge the battery.
4.4 OVER VOLTAGE PROTECTION
Over voltage protection is provided through the internal PWM controller.
16 | SAMLEX AMERICA INC.
5.1
!
WARNING!
a) Before commencing installation, please read the safety instructions explained
in Section 1.
b) It is recommended that the installation should be undertaken by a qualied,
licensed / certied electrician.
c) Various recommendations made in this manual on installation will be super-
seded by the National / Local Electrical Codes related to the location of the
unit and the specic application.
MISE EN GARDE!
a) Avant de commencer l’installation, veuillez lire les consignes de sécurité
décrites dans la section 1.
b) Il est recommandé que l’installation doit être effectuée par un technicien
qualié, autorisé / électricien certié.
c) Différentes recommandations faites dans ce manuel sur l’installation
sera remplacée par la National / les codes électriques locaux liés à
l’emplacement de l’unité et l’application spécique.
5.2 INSTALLATION DIMENSIONS
Refer to Section 2, Figs 2.2 for installation dimensions.
5.3 LOCATION OF INSTALLATION
Please ensure that the following requirements are met:
Working Environment: Indoor use.
Cool: Heat is the worst enemy of electronic equipment. Hence, please ensure that the
units are installed in a cool area that is also protected against heating effects of direct
exposure to the sun or to the heat generated by other adjacent heat generating devices.
Well ventilated: The unit is cooled by convection and by forced air-cooling by temperature
controlled fan on the bottom of the unit. The fan at the bottom of the unit draws cool
air from air intake openings on the sides and discharges hot air through the exhaust
openings under the fan. To avoid shut down of the unit due to over temperature, do
not cover or block the ventilation / suction / exhaust openings or install the unit in an
area with limited airow. Keep a minimum clearance of 10” around the unit to provide
adequate ventilation. If installed in an enclosure, openings must be provided in the
enclosure, directly opposite to the air-suction and air-exhaust openings of the unit.
Dry: There should be no risk of condensation, water or any other liquid that can enter
or fall on the units.
SECTION 5 | Installation
16 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 17
SECTION 5 | Installation
Clean: The area should be free of dust and fumes. Ensure that there are no insects or
rodents. They may enter the units and block the ventilation openings or short circuit
electrical circuits inside the units.
Protection against re hazard: The unit is not ignition protected and should not be
located under any circumstance in an area that contains highly ammable liquids like
gasoline or propane as in an engine compartment with gasoline-fueled engines. Do not
keep any ammable / combustible material (i.e., paper, cloth, plastic, etc.) near the unit
that may be ignited by heat, sparks or ames.
Accessibility: Do not block access to the front panel. Also, allow enough room to access
the AC inlet and the DC wiring terminals and connections at the back of the unit, as
they will need to be checked and tightened periodically.
Preventing Radio Frequency Interference (RFI): The unit uses high power switching
circuits that generate RFI. This RFI is limited to the required standard – FCC Part
15(B), Class B. Locate any electronic equipment susceptible to radio frequency and
electromagnetic interference as far away from the unit as possible. For additional
information, please read Section 7 titled “Limiting Electromagnetic Interference (EMI)”.
5.4 MOUNTING ORIENTATION
The unit has air intake openings on the sides and exhaust openings at the bottom for
the cooling fan. The unit should be mounted in such a manner so that small objects
should not be able to fall easily into the unit from these openings and cause electrical /
mechanical damage. Also, the mounting orientation should be such that if the internal
components overheat and melt / dislodge due to a catastrophic failure, the melted /
hot dislodged portions should not be able to fall out of the unit on to a combustible
material and cause a re hazard. The size of openings has been limited as per the
safety requirements to prevent the above possibilities when the unit is mounted in the
recommended orientations. In order to meet the regulatory safety requirements, the
mounting has to satisfy the following requirements:
- Mount on a non-combustible material.
- The mounting surface should be able to support the weight of the unit
- Mount horizontally on a horizontal surface (e.g. table top or a shelf).
- Mounting horizontally on a vertical surface – The unit can be mounted on a vertical
surface (like a wall) with the DC output terminals either facing up or down.
!
WARNING!
Mounting the unit on a vertical surface with the ventilation slots on the sides
facing up / down is NOT recommended. As explained above, this is to prevent
(i) falling of objects into the unit through the slots causing short circuit or (ii)
falling out of dislodged overheated / melted components on to a combustible
material in case of catastrophic internal failure.
18 | SAMLEX AMERICA INC.
SECTION 5 | Installation
MISE EN GARDE!
Montage de l’appareil sur une surface verticale avec les fentes de ventilation
sur les côtés vers le haut / vers le bas n’est pas recommandé. Comme
expliqué ci-dessus, il s’agit d’éviter que (i) la chute d’objets dans l’unité à
travers les fentes provoquant un court-circuit ou (ii) en tombant de délogé
/ composants surchauffés fondu sur un matériau combustible en cas de
défaillance interne catastrophique.
5.5 AC SIDE CONNECTION
120VAC power is fed to the unit through detachable, 120 VAC power cord supplied with
the unit. The power cord has the following specications:
• Length of the cord: 6 ft
• Cable : 3 conductors (Line – black; Neutral – white; Grounding - Green), each AWG #18
• 15A Connector for power supply end: “IEC 60320 – C13” female connector ( Insert
this end into the AC Power Inlet on the unit (2, Figs 2.1)
• 15A Plug for connecting to 120 VAC outlet: NEMA5-15P
NOTE: If the unit is required to be operated from 230VAC, its internal jumper setting
should be rst set for 230VAC operation as per instructions given at Section
3.1.1. Also, appropriate detachable cord should be used that has “IEC 60320 –
C13” female connector for the power supply end and a plug on the other end
with 3 pin conguration to suit the 230V country specic outlet.
5.6 DC OUTPUT TERMINALS
5.6.1 DC Output Terminals: DC output is provided as follows:
• Red Positive Terminal for Load (4, Figs 2.1) and for Battery (6, Fig 2.1):
o Tubular Hole – Diameter 5 mm / 0.2”
o *Set Screw: 5/64” Hex Socket Head Screw; #10, 24 TPI, 5/16” long
• Black Negative Terminal for Load (3, Figs 2.1) and for Battery (5, Fig 2.1):
o Tubular Hole – Diameter 5 mm / 0.2”
o *Set Screw: Hex 5/64” Socket Head screw; #10, 24 TPI, 5/16” long
*NOTE: The following have been provided for convenience:
a) 5/64” Hex / Allen Key for the Hex Socket Head Screw.
RETAIN THE HEX / ALLEN KEY FOR FUTURE USE
b) 2 spare Hex socket head screws
5.6.2 Pin Type of Terminal Lugs for Wiring to be Connected to DC Output Terminals:
The DC output terminals have a tubular hole with a set screw (See Section 5.6.1 above for
specications). As the DC terminals have been provided with a set screw, do not connect
bare stranded wire end directly to the DC output terminal as the strands will spread out
when the set screw is tightened and all the strands may not be pinched rmly under
the set screw. This will result in (i) reduction in effective area of cross section for current
conduction leading to increased voltage drop and overheating along output wiring and
18 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 19
(ii) sparking / loose connection under the set screw leading to overheating / melting of
the plastic material of the terminals. The ends of stranded wiring to be connected to
the DC output terminals should be crimped to Pin Type of Terminal Lugs that have been
provided with the unit (see Fig 5.1). After crimping the Terminal Lugs, use insulating heat
shrink tubing or tape to insulate the bare cylindrical portion of the lugs.
Manufacturer: K.S. Terminals
Part No. : PTNB10-12
Wire gauge: Up to AWG #8 (10 mm
2
)
Fig 5.1 Pin type of terminal lugs provided for termination of
stranded wiring to be connected to the DC input terminals.
5.7 DC OUTPUT CONNECTIONS
Load Connection: The load is connected to the terminals marked “Load +” (4, Fig 2.1)
and “Load - ” (3, Fig 2.1) through 32V, 25A Fuse (F2, Fig 2.1) (See details below under
heading “External Fuses”). Please ensure that the polarity of the connection is correct -
Positive of the load to the “Load +” terminal (4, Fig 2.1) and the Negative of the load to
the “Load - ” terminal (3, Fig 2.1).
Battery Connection: The Positive of the battery is connected to the “Battery +” terminal
(6, Fig 2.1) and the Negative of the battery to the “Battery - ” terminal (5, Fig 2.1) through
32V, 25A Fuse (F1, Fig 2.1) [Refer to Section 5.9 for details].
Recommended Battery Capacity: Battery should not be charged at very high current.
Normally, as a Rule of Thumb, the maximum charging current should be limited to 10%
of the Ah capacity at 20 Hour Rate unless higher current is allowed by the manufacturer.
Higher charging current produces higher heating which reduces the life of the battery.
Further, higher charging current will not re-charge the battery to full 100% capacity
unless the charging voltage is increased proportionately. It is recommended that the
capacity of the battery used with this unit should be in the range of 40 to 100Ah.
5.8 DC OUTPUT WIRE SIZING
Use AWG #10, 90°C / 194°F insulation wire for the load and battery connections for a
distance of up to 3 ft. Thicker wire will be required for distance longer than 3 ft. (See
Table 5.1). USE THICKER WIRE OUT THE 2 SIZES CALCULATED BASED ON THE FOLLOWING
2 CONSIDERATIONS:
5.8.1 Safety of Conductor Insulation
Current (I) owing through resistance (R) of conductor produces power loss (I
2
R) in
the form of heat which results in temperature rise in the conductor. Temperature rise
is higher for higher current, higher resistance (longer length and thinner cross section
produce higher resistance) and higher ambient temperature. Temperature rise higher
SECTION 5 | Installation
20 | SAMLEX AMERICA INC.
than the temperature rating of conductor insulation will melt / burn the insulation
resulting in possibility of electrical shock and re. The National Electrical Code species
maximum current ow (Ampacity) through a particular wire size [normally specied
as cross-section in American Wire Gauge (AWG)] for a particular temperature rating of
conductor insulation, ambient temperature and type of surrounding medium (like free
air, raceway, etc.). NEC further species that the Ampacity of the wire should be 1.25
times the maximum current ow. The maximum output current in the unit is 25A.
- The maximum output current in the unit is 25A. Hence, the Ampacity of the
wires as per NEC should 1.25 x 25 = 31.25A or say 40A
- As per NEC Table 310.15(B)(17) for 90°C / 194°F conductor insulation, free air,
40°C / 104°F ambient and Ampacity of 40A, the minimum conductor size should
be AWG #10.
5.8.2 Limiting Voltage Drop along the Length of the Wiring
Current owing through resistance produces voltage drop. Voltage drop is higher
for higher resistance (longer length and thinner cross section produce higher resistance).
Excessive voltage drop across the length of wires connecting the power source to the
load produces excessive power loss and may also shut down the load due to under
voltage created at the load end. Hence, the voltage drop should be kept to the
minimum at around 2% by using thicker wires for longer distances. Table 5.1 given
below shows thickness of wire for 2% voltage drop consideration for 12 V battery / load
when carrying 25A:
TABLE 5.1: RECOMMENDED WIRE SIZES FOR 3 FT., 6FT. AND 10 FT. DISTANCES
Rated Current
Size of Wiring for 2% Voltage Drop
3 ft. 6 ft. 10 ft.
25A AWG #10 AWG #8 AWG #6
As mentioned above, the calculated wire size is AWG #10 when considering safety of
conductor insulation. Hence, use AWG #10, 90°C / 194°F insulation wire for the load and
battery connections for a distance of up to 3 ft. If the distance of the Load / Battery is >
3 ft., the size on account of 2% voltage drop and 25A current ow consideration will be
thicker than AWG #10 as shown in Table 5.1 above and these thicker sizes should be used.
5.9 EXTERNAL FUSES ON THE BATTERY AND LOAD SIDES
A battery is an unlimited source of current that can drive thousands of Amperes of cur-
rent into a short circuit leading to overheating and burning of wiring / circuit compo-
nents along the path from the battery terminals to the point of short circuit. This can
cause injury and is a re hazard. Similarly, a power source is also be capable of driving
considerably high value of current into a short circuit on the load side and causing
damage as above (the current will, however, be limited to the maximum rated overload
current and not unlimited as in the case of a battery). Appropriate fuse should, there-
fore, be used in series with the battery Positive post / Load terminal of power source to
protect against the above safety hazard. FOR EFFECTIVE PROTECTION, APPROPRIATE
SIZES OF FUSES SHOULD BE LOCATED AS FOLLOWS:
SECTION 5 | Installation
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