SamplexPower SEC-4825BRM Owner'S Manual Download Page 2

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2 | SAMLEX AMERICA INC.

OwNer'S MaNual |

Index

Section 1

Safety Instructions ................................................................. 3

Section 2

Layout, Dimensions & Input/Output Connections ................ 5

Section 3

Design & Principle of Operation ........................................... 7

Section 4

Protections ........................................................................ 19

Section 5

Installation ........................................................................ 21

Section 6

Operation ........................................................................ 23

Section 7

Limiting Electro-Magnetic Interference (EMI) ...................... 25

Section 8

Troubleshooting Guide ....................................................... 28

Section 9

Specifications ..................................................................... 31

Section 10

Warranty

........................................................................ 33

Summary of Contents for SEC-4825BRM

Page 1: ...N 1 DC Power System SEC 4825BRM Please read this manual before installing the unit Owner s Manual ...

Page 2: ...imensions Input Output Connections 5 Section 3 Design Principle of Operation 7 Section 4 Protections 19 Section 5 Installation 21 SECTION 6 Operation 23 Section 7 Limiting Electro Magnetic Interference EMI 25 Section 8 Troubleshooting Guide 28 Section 9 Specifications 31 Section 10 Warranty 33 ...

Page 3: ...gged into the corresponding NEMA L5 30R outlet the chassis of the unit is automatically connected to the Earth Ground through the Equipment Grounding Conductor that is connected to the grounding slot of the outlet The pow er cord must be plugged into a corresponding NEMA L5 30R outlet that is properly installed and grounded in accordance with all local codes and ordinances Never alter the power co...

Page 4: ...y manufacturer s recommendations Never smoke or allow a spark or flame 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 batteries The batteries can produce a short circuit current high enoug...

Page 5: ... output PSM is not synchronizing OFF No output Defective 6 Red LED for fan failure or over temperature of heat sink on the PSM Steady ON Fan failure or PSM over temperature Back View 7A Positive Load Terminal Tubular Hole 5 16 Diameter Set Screw 5 16 X 3 8 Long x 24 TPI 7B Negative Load Terminal 8A Positive Battery Terminal 8B Negative Negative Terminal 9 Cooling Fan 2 x 48V fans Run continuously ...

Page 6: ...l including protrusions Wide W 482 6 mm 19 00 Depth D 407 6 mm 16 05 Height H 87 7 mm 3 45 2 Dimensions Mounting Holes Width W 466 73 mm 18 38 Height H 76 2 mm 3 00 407 6 482 6 87 7 466 73 482 6 407 6 407 6 7 94 Section 2 Layout Output Connection Dimensions Fig 2 2 Dimensions ...

Page 7: ...dules PSM that are connected in parallel and operate under forced current share control to deliver a total of 25A Each PSM is a stand alone 55V Power Supply which delivers up to a maximum of 5A continuous By equalizing the output currents uniform thermal stress of the individual PSMs is ensured which has utmost importance for long term reliability of elec tronic components The operating principle ...

Page 8: ... 8A 8B Fig 2 1 will always be clamped to the actual voltage of the battery corresponding to its State of Charge If AC input power fails the DC load will be instantaneously transferred to the external 48V backup battery and the battery will start discharging When AC input power is restored the DC load will once again be transferred instantaneously to the Power Supply Section and the external backup...

Page 9: ... effective series resistance of 6 Ohm This effective series resistance of 6 Ohm will limit the maximum charging current to 2A The charging current will be determined by the following equation Battery s internal impedance and battery cable resistance have been disregarded as their values are negligible as compared to the 6 Ohm effective series resistance Charging Current Load Terminal Voltage Batte...

Page 10: ...e verse biased and the discharged battery will be taper charged through 6 Ohm effective resistance of R1 R2 NOTE The value of charge limiting resistors R1 and R2 is based on a typical 48V 25Ah deep cycle marine battery If a different type of battery is used the value of the resistor should be adjusted to meet associated charging requirements REMOTE MONITORING OF OPERATIONAL STATUS A provision has ...

Page 11: ...es from an external voltage source and hence maximum isolation is provided Ability to generate TTL logic signals with Vcc of 3 3V 5V Fig 3 3B for 5V Vcc Drive relays LEDs with Vcc of up to 35VDC e g 5V 12V 24V and drive current of up to 50 mA Figs 3 3C and 3 3D Ability to combine the signals OR d to form a single signal sharing common Logic Ground Item Pin No Color Code of Wire Output Pins of Opto...

Page 12: ...al Fig 3 3B 5V TTL Logic Drive Vcc 5V Vcc Ground To Micro controller PSM 1 Normal Low 0 to 0 5V PSM 1 Defective High 2 7V to 5V Fig 3 3C 5V 12V 24V Relay Drive Vcc 5V 12V 24V Max 35V IN4001 From Fig 3 3A 20 7 Relay 5V 12V 24V Choose coil resistance to limit coil current to 50 mA NC Common NO PSM 1 Normal Relay energizes PSM 1 Defective Relay de energized Vcc Ground PSM 1 Normal LED ON PSM 1 Defect...

Page 13: ...spectively of the DB25 Connector Fig 3 2 Operation at Remote Monitoring Location Monitoring of status from the DB 25 Connector can be undertaken at the remote monitoring location in 3 ways shown in Fig 3 3B 3 3C and 3 3D Section 3 Design Principle of Operation L N S2 S1 LED 1 LED 2 S3 S4 S6 S 5 JUMP 1 VCC VR1 NOT TO SCALE Legend S1 to S4 Holes for 4 screws to fasten the module to the chassis S5 S6...

Page 14: ...ion and their PSM x LEDs will remain continuously lighted and the output voltage of the common DC bus before Schottky Diode D1 will be equal to the set voltage If the output voltage of any module is higher than the set voltage it will become the Master and it s associated PSM x LED will remain continuously lighted However the other Modules with voltage lower than the set voltage will Section 3 Des...

Page 15: ... voltage of the all the individual modules will be required to be adjusted to the desired value As explained under Operation Of Battery Back Up And Charging Section on page 8 although the output voltage of the module at terminals S5 and S6 Fig 3 4 or at the common DC bus before the Schottky Diode D1 is tightly regulated at the preset value of 55V the voltage at the output terminals Load and Load w...

Page 16: ... power supply Only PSM No 2 will operate Adjust the output voltage of this module to the same set value with the help of potentiometer VR1 Fig 3 4 Measure the output voltage of the module at the screw terminals S5 and S6 Fig 3 4 8 Continue to adjust the voltage of the remaining Module Nos 3 4 and 5 individu ally as explained above making sure that the AC input power is connected to only the module...

Page 17: ...d offs under holes S1 to S6 Fig 3 4 Remove these screws and then remove the defective Module 7 If this module has Temperature Sensor mounted on its heat sink remove the Tem perature Sensor by removing its holding screw 8 Place the new module on the stand offs with the L an N terminals Fig 3 4 towards the front panel Align the holes and fix the module with the 6 screws WARNING Please ensure that sc...

Page 18: ...o ensure that the voltages of the 4 remaining active individual paral leled modules are set exactly at 55V For this follow instructions given under Proce dure for Adjusting Output Voltage of Modules page 16 8 Replace the top cover Power on the unit and confirm that the PSM Status LEDs for the 4 modules are lighted COOLING Due to modular design each Power Supply Module has its own heat sink that is...

Page 19: ... the entire load current will be supplied by the Power Supply Section and will be limited to a maximum of 30A by its Current Limit Circuitry If the load tries to draw a higher current than the current limit value of 30A the output voltage at the Load Terminals and the Battery Terminals will not be regulated and will drop below 58 5V 0 3V If the load impedance is further reduced the current will re...

Page 20: ...additional current supplied by the battery Additional battery current supplied into the short circuit on the load side Short circuit current 30A from the Power Supply Section For example if a short circuit current of 150A tries to flow for 100 ms 30A will be supplied by the Power Supply Section and the balance 120A will be supplied by the battery As the external 25A Fuse F2 on the load side will s...

Page 21: ...f the unit 12 Fig 2 1 WARNING In both the above conditions immediate remedial action must be taken to ensure ad equate cooling Defective fan s should be replaced availability of cool airflow should be checked and ensured load should be decreased PLEASE NOTE THAT THE UNIT WILL NOT SHUT DOWN AUTOMATICALLY AND PROLONGED OPERATION IN THE ABOVE OVER TEMPERATRE CONDITIONS MAY DAMAGE THE UNIT WARNINGS Pl...

Page 22: ...arged 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 inc...

Page 23: ... power is not available and a battery has been connected for backup func tion the load will be powered by the battery and the battery will continue to discharge as long as the load is in ON condition When the load is not delivering power it still draws current for its self consumption called No Load Current When AC input power is not available switch OFF the load if not required otherwise the batt...

Page 24: ...OFF Switch 1 Red light inside the ON OFF switch will switch OFF CHARGING AND BACKUP OPERATION Charging current will be proportional to the discharged state of the battery and is lim ited to maximum of 2A when the battery is completely discharged Standing Voltage of 42 8V The current will taper down from 2A as the battery gets charged and its voltage rises When the battery is fully charged the curr...

Page 25: ...ction is not used external backup battery is not connected the unit will work as a normal power supply with ability to supply 25A continuous at 54 5V 0 3 VDC at the Load Terminals 7A 7B Fig 2 1 The maximum overload current will be limited to 30A Under overload conditions the output voltage will not be regulated and will drop Section 7 Limiting Electro Magnetic Interference EMI CAUTION Conducted an...

Page 26: ...on of the power sup ply can be disturbed due to RF noise getting coupled into the power supply Thus the power supply may generate excessive RF noise and lose output voltage regulation due to excessive transmitter energy being coupled through the AC DC lines to the power supply s regulator feedback path This may be due to antenna being too close or due to the antenna or feed system not radiating pr...

Page 27: ...he skin contact resist ance is lower i e if the skin is wet or wounded This leakage current does not return to the power source but is dissipated in Earth Ground A leakage current of 5mA could produce lethal electrical shock Ground Fault Circuit Interrupter GFCI is used for safety against electrical shock due to leakage GFCI measures the difference between the current sent to the load and returned...

Page 28: ...of Master Slave operation for forced current share Forced Share Control Circuitry of the module s is defective Adjust the output voltage of all the modules to exactly 55V as explained in the Adjustment Procedure at page 15 If after carrying out the above adjustment the problem still exists under no load then apply 5A load If flashing stops under load it means that the internal static load is not s...

Page 29: ...m Possible Cause Remedy ON OFF Switch is ON Switch is NOT lighted Load is ON and is operating normally Output voltage at the Battery Terminals is 54V to 54 6V and is dropping Output voltage at the Load Terminals is 0 3V 0 1V lower than the Battery Terminals and is dropping No AC power from the AC outlet AC Input Breaker is tripped Check AC power is available at the AC outlet Breaker feeding the AC...

Page 30: ...sal of battery polarity Check that the polarity of battery connections is correct Replace the fuse Check for short circuit in the battery wiring and correct Replace the fuse GFCI outlet GFCI breaker supplying AC power to the unit trips when the unit is switched ON Additional RF noise current from the unit that is filtered to Earth Ground increases the net Leakage Current on the GFCI outlet GFCI br...

Page 31: ...vs Current Charateristics of 25A Fuse F2 Battery Charging type of Charging Taper Type of Float Charging at 54V to 54 6V Output Current Limit at Battery Terminals Battery Backup 2A When battery is completely discharged to Standing Voltage of 45 4V Peak Efficiency 85 5 External Backup Battery Type Voltage Lead Acid 48V Capacity 10Ah to 25 Ah Protections Short Circuit Overload External 25A Load Side ...

Page 32: ...attery Connections Terminal with Tubular Hole Diameter 5 16 and set screw 5 16 24 TPI 3 8 long Battery wires Minimum AWG 10 Environmental Operating Temperature Range 0 C 32 F to 40 C 104 F Dimensions Weight Dimensions W x D x H 482 6 x 407 6 x 87 7 mm 19 00 x 16 05 x 3 45 in Weight 11 4 kg 25 lb NOTE Above specifications are subject to change without notice Section 9 Specifications ...

Page 33: ...g a reasonable number of opportunities to do so Warranty service shall be performed only by the Warrantor Any attempt to remedy the defect by anyone other than the Warrantor shall render this warranty void There shall be no warranty for defects or damages caused by faulty installation or hook up abuse or misuse of the equipment including exposure to excessive heat salt or fresh water spray or wate...

Page 34: ...34 SAMLEX AMERICA INC Notes ...

Page 35: ...Notes ...

Page 36: ...0 561 5885 Fax 888 814 5210 Local Numbers Ph 604 525 3836 Fax 604 525 5221 Website www samlexamerica com USA Shipping Warehouse Kent WA Canadian Shipping Warehouse Delta BC Email purchase orders to orders samlexamerica com 11001 SEC 4825BRM 0114 ...

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