Samlexpower SEC-40BRM Specifications
Contents
1. Following additional guidelines may be followed to reduce the effects of RF noise Use additional appropriate AC radio frequency interference RFI power line filter immediately before the AC input of the power supply For example 125VAC 30A filter F1700DD30 from Curtis Industries www curtisind com or similar Filtered ferrite coated cord set www emceupen com is another choice These cord sets with integral line interference filters reduce common and differential mode interferences over a wide frequency range Because they are shielded they are also effective against radiated interferences In addition to the built in filter networks the cable conductors are coated with an RF absorbing ferrite compound This provides additional attenuation at high frequencies that is lacking in most regular LC filters The RF absorption of the ferrite coated cable avoids resonance s at high frequencies reducing the conducted and radiated RF noises even further Use additional appropriate DC radio frequency interference RFI power line filter immediately after the dc output of the power supply For example 80VDC 100A filter from DC series by Corcom www corcom com or 80VDC 100A filter from FD series by Curtis Industries www curtisind com or similar 14 Twist the positive and negative wires from the output of the power supply to the radio The DC side positive and negative outputs of these power supplies are iso la2. EXPANDABLE DC POWER SUPPLY SAMLEXK AMERICA N 1 DC Power System with Battery Backup Charging Function MODELS SEC 40BRM SEC 60BRM SEC 80BRM SEC 100BRM INSTALLATION amp OPERATING MANUAL Please read this manual before operating your power supply PROVIDES N 1 REDUNDANCY ALLOWS CONNECTION OF EXTERNAL BATTERIES FOR BACKUP EXPAND OUTPUT POWER BY ADDING POWER MODULES UP TO 100 AMPS CONTINUOUS POWER VOLT AMPERE METER OPERATION STATUS L E D FAN FAILURE ALARM AND WARNING L E D REMOTE MONITORING AND INDICATION 19 RACK MOUNT 2 YEAR WARRANTY TOLL FREE TECHNICAL SUPPORT TABLE OF CONTENTS Topic Important safety instructions Description and application Design and principle of operation Cooling and warning for fan failure Front panel controls and indicators Rear panel controls Protections Installation and operation Operation of battery back up Output voltage adjustment Installation and removal of modules Trouble shooting Limiting electromagnetic interference Specifications Appendix Figures 1 to Warranty information Notes Page 1 2 7 8 9 9 10 11 12 13 14 15 16 17 18 19 20 IMPORTANT SAFETY INSTRUCTIONS Please read before using your power supply CAUTION ALL ELECTRICAL INSTALLATIONS MUST MEET LOCAL AND NA TIONAL WIRING CODES AND SHOULD BE PERFORMED BY A QUALI FIED ELECTRICIAN OPERATION OF COOLING FAN THE HEAT PRODUCED IS EXTRAC
3. ELO 3 4 5 Fi O The following output connectors have been provided Not shown 41 REAR PANEL CONNECTORS 1 Load Positive Load Negative LOAD CONNECTORS For connecting to the D C Load 2 Positive Battery Negative BATTERY CONNECTORS For connecting external battery for un interrupted D C power to the load REMOTE MONITORING AND SIGNALLING A provision has been made for remote signaling and monitoring of the following operational conditions and parameters 1 Operational status of the 5 Power Supply Modules PSM 2 Failure condition of the cooling fan s 3 Availability of AC input power 4 Output voltage measurement 5 Output current measurement Voltage across an internal shunt with Shunt ratio of 50 mV 100 A or 0 5 mV per Amp Signaling of operational conditions as at serials 1 2 and 3 above is opto coupled with open collector NPN transistor outputs The collector and emitter of each opto coupled transistor are accessible to the external user interface through the 25 pin D Sub connector Each open collec tor opto coupled NPN transistor can provide a maximum of 50 mA with a collector to emitter voltage of up to 35 V Outputs for voltage and current measurements at Serials 4 amp 5 above are direct analogue volt ages The pin out of the 25 pin D Sub connector providing the above signals for user interface is given below Item Pin Color Code Output Pin of Oper
4. Samlex America Inc the Warrantor 110 17 Fawcett Road Coquitlam BC V3K6V2 Canada 800 561 5885 604 525 3836 19 Attach copy of receipt here for your records Date purchased Purchased from Additional notes 20 SAMLEX AMERICA Thank you for purchasing a Samlex power supply product Samlex America Inc 110 17 Fawcett Road Coquitlam B C V3K 6V2 Canada SEC 40 60 80 100BRM _Nov2007
5. 14 2V For this follow instructions given under Procedure on page 9 9 Replace the top cover Power on the unit and confirm that the PSM Status LEDs of all the installed mod ules are lighted 10 REMOVING A DEFECTIVE MODULE 6 Remove the top cover plate by unscrewing the 10 screws Locate the defective module Remove the 6 screws from S1 to S6 Remove the input power supply wires from terminals L and N Insulate the wire terminals with insulating tape Remove connectors from terminals LED 1 amp LED 2 Remove the SHARE BUS wire female socket connector from the terminal JUMP1 If the defective module is not being replaced immediately and if the unit is required to be operated without this defective module IS MANDATORY TO SHORT THE TWO FEMALE SOCKETS ON THIS UNUSED FEMALE CONNECTOR WITH A SHORTING LINK SEE FIG 3 THIS WILL ENSURE THAT THERE IS NO BREAK IN THE SHARE BUS DAISY CHAIN AND THAT ALL THE JUMP1 TERMINALS ARE INTERCONNECTED The module can now be removed TROUBLE SHOOTING POWER ON OFF SWITCH DOES NOT LIGHT WHEN SWITCHED ON Check that power is available in the AC outlet Check that the power cord plug is properly plugged in BREAKER TRIPS The breaker has tripped due to abnormal condition Call technical support FAN FAILURE LED LIGHTS UP AND BUZZER IS SOUNDED One or both of the fans have stopped Forced cooling has failed due to defect in the cooling
6. fan s Switch off the unit immediately Fan s needs to be replaced DO NOT USE THE UNIT TILL THE DEFECT IS RECTIFIED IT IS PRO HIBITED TO USE THE UNIT WITHOUT FORCED COOLING Call techni cal support If both the fans are running the small fan status monitoring PCB may be defective Call technical support 11 PSM STATUS LED S DOES NOT LIGHT UP The associated module has become defective The unit will still operate normally as the remaining working modules will share a higher load The unit will go into current limit and the output voltage will drop if the load drawn is more than the combined maximum rated output of the remaining modules Reduce the load so that the maximum load drawn is less than the combined maximum rated output of the working modules Remove the defective module and replace with a new module OUTPUT VOLTAGE DROPS ON LOAD The unit has gone into current limit as the load being drawn is more than the combined maximum rating of the working modules This may also result if one or more modules has failed Check that all the modules are operating properly If a module has failed its green LED would extinguish or flash Reduce the load drawn to a value less than the combined maximum rated output of the working modules If the voltage does not rise to the rated voltage of 13 65 V to 13 35 V then switch off all the loads If the voltage in this condition is also low switch off the unit and contact technical
7. sufficient to provide adequate feedback signal strength resulting in shut down of one or more modules when no external load is present The associated PSM Status LED will flash and also the associated signal for remote indication will oscillate between High and Low As soon as external load is applied to the unit the feed back signal strength will increase and the PSM s that were shut down will also operate normally The output is delivered through an isolating Schottky diode to enable connection of external battery for un interrupted DC power output The external backup battery is kept charged by taper charging through a series resistor SEC 100BRM has 5 PSMs of 20 A each providing a total of 100 A SEC 80BRM has 4 PSMs of 20 A each providing a total of 80 A SEC 60BRM has 3 PSMs of 20 A each providing a total of 60 A SEC 40BRM has 2 PSMs of 20 A each providing a total of 40 A COOLING AND WARNING FOR FAN FAILURE The heat generated due to internal power dissipation is removed by forced cooling through two high power D C fans mounted at the back of the unit which suck air from the vents on the sides of the unit amp blow outwards from the rear of the unit IT IS EXTREMELY IMPORTANT THAT THE DISCHARGE SIDE OF THE FANS AND THE SUCTION SIDES OF THE VENT SLOTS ARE NOT BLOCKED 3 A warning circuit monitors the operational condition of the fans In case of a fan failure a buzzer will sound and the red LED indicating FAN FAILURE will ligh
8. support ONE OR MORE PSM STATUS LED S FLASHES The output voltage of the individual modules is not the same or the forced shared control circuitry of the module s is defective Adjust the voltages of the modules to 14 2V as explained on page 8 If the problem still exists contact technical support If the one or more PSM status LED s flash when no external load is con nected it may mean that the internal pre load current is not sufficient to provide adequate feedback signal for the current share control circuitry Apply external load If the flashing stops the associated PSM s are nor mal If flashing continues even after applying an external load contact tech nical support 12 LIMITING ELECTROMAGNETIC INTERFERENCE EMI 1 Switched mode power supplies SMPS employ high frequency switching and thus are a source of radio interference a recipient of radio interference and a conduit of radio interference Older linear type transformer based power supplies do not employ high frequency switching voltages and will be quieter as compared to switching type of supplies The primary emission sources originate in the switching devices due to their fast switching current transitions harmonics of the switching frequency and broadband noise created by under damped oscillations in the switching cir cuit The secondary source is from the bridge rectifier both rectifier noise and diode recovery The AC input rectifier ca
9. 20 V 60 Hz input power and unplug the power cord from the mains outlet NOTE Please refer to the layout diagram of the module at Figure 1 located on page 17 UPGRADING TO HIGHER CAPACITY INSTALLING ADDITIONAL MODULE S Additional optional module s Model No SEC 2012MPSB can be added to upgrade the output current capacity of SEC 40BRM SEC 60BRM SEC 80BRM by steps of 20A to a maximum of 100A For example an SEC 40BRM 40 A with 2 modules can be upgraded to SEC 60BRM 60A by adding 1 more module or to SEC 80BRM 80A by adding 2 more modules or to SEC 100BRM 100 A by adding 3 more modules The optional module SEC 2012MPSB comes with an LED and LED holder It s output voltage is pre set at 14 2 Volts The procedure to install additional module s is as follows 1 Remove the top cover plate by unscrewing the 10 screws 2 Each module sits on 6 stand offs under the holes S1 to S6 Fig 1 Additional module s are to be installed in the vacant space s adjacent to the right of the existing module Remove the screws from the 6 stand offs for the adjacent vacant space for the module 3 Place the module on the stand offs with the L an N terminals Fig 1 towards the front panel Align the holes and fix the module with the 6 screws WARNING Please ensure that screws S5 and S6 are very tight as the pads under these two screws connect the output of the module s to the DC bus bar underneath A loose connection under these screws wi
10. C 1 the voltage at the output terminals Load and Load will vary slightly due to the forward voltage drop of the isolating Schottky Di ode D1 and the drop along the DC bus bar and wiring The voltage at the output terminals LOAD and LOAD will be as follows At no external load Approx 14V At 10 A load Approx 13 8V At loads gt 10A Approx 13 8V minus 5mV per Amp above 10A When there is a requirement of un interrupted D C power to the load an external battery may be connected at the terminals Battery and Battery When the input A C power is available the load current is supplied by the power supply through isolating Schottky Diode D1 At the same time the battery is charged through resis tors R1 4 R2 These resistors will limit the maximum charging current to about 8 Amperes If the input A C power is interrupted the external battery feeds the load instantane ously through the Schottky Diode D2 D2 will by pass the resistors R1 8 R2 Voltage available to the load will be approximately 0 4V lower than the battery voltage due to forward voltage drop across D2 Availability of AC power is signaled for remote monitoring through an opto coupled signal through the D Sub connector see page 5 under Remote monitoring amp Signal ing This signal may also be used to indicate that the load is being powered by bat tery In case external battery is used for battery back up When the input AC power returns the ba
11. KER e MODULE FUSE 250V 4A e UNIT HAS A BREAKER 250 V 20 A DIMENSIONS 19 Rack Mount 2U height 19 X 15 9 X 3 6 POWER CORD 12 AWG 3 CONDUCTOR POWER CORD PLUG e SEC 100BRM 125V 30A NEMA L5 30P TWIST LOCK TYPE e SEC 40BRM 60BRM 80BRM 125V 20A NEMA 5 20P WEIGHT LBS 20 5 22 23 5 25 NOTE SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 16 juaunsn pe JNAJNO 104 asny sng eys 10 peura Jedunp JOJ SNJEJS WSd 37 104 euro UOIJBJIPUI ajowa JO 5 104 peure sem Ajddns jndul ZH 09 AOZ 20 y pue 1 sieg pue SAIJISO4 94 0 M919S Z JO SISSEUJ ay 0 ay p ainpow Ajddng jo INOABT andi 31925 OL LON LUA bd 31 N91 95 95 YS 0115 Figure 1 17 Figure 2 Daisy Chaining of Share BUS jumpers Jump 1 PSM 1 PSM 2 PSM 3 PSM 4 PSM 5 1 1 1 1 1 H BER HR ES Printed Circuit Board Jump 1 Jump 1 Jump 1 Jump 1 Jump 1 1 Female socket terminal of the daisy chain 2 Male 2 pin terminal marked Jump 1 on the Power Supply Module CONTINUITY OF DAISY CHAIN CONNECTIONS Removing any end mo
12. ORD WITH A 2 PIN PLUG THERE WILL BE NO GROUNDING CONNECTION IN THIS TYPE OF PLUG WHICH IS A SHOCK AND FIRE HAZARD 2 THE EXTENSION CORD WIRE SIZE SHOULD BE MINIMUM 12 AWG 20 A LOAD AND BATTERY CONNECTIONS THE LOAD 8 BATTERY TERMINALS ON THE POWER SUPPLY HAVE A TUBU LAR HOLE OF DIAMETER 8mm 0 31 WITH A SET SCREW ALWAYS ENSURE THAT THE CONNECTIONS ARE SECURE AND THE SCREWS ARE TIGHTENED PROPERLY LOOSELY TIGHTENED CONNECTIONS RESULT IN EXCESSIVE VOLTAGE DROP AND MAY CAUSE OVERHEATED WIRES AND MELTED INSULATION THE ENDS OF THE CABLES TO BE CONNECTED TO THE LOAD AND BATTERY TERMINALS ON THE POWER SUPPLY SHOULD HAVE PIN TYPE OF CONNEC TOR FOR MAKING A FIRM CONNCECTON 4 PIECES OF PIN TYPE CONNEC TORS ARE ENCLOSED WITH THE POWER SUPPLY CRIMP THESE TO THE ENDS OF THE CABLES USE MULTI STRANDED WELDING TYPE CABLE OR BATTERY CABLE NEOPRENE SYNTHETIC INSULATION 90 C USE PROPER SIZE OF CABLE AS INDICATED BELOW TO CONNECT ANY DEVICE TO THE POWER SUPPLY THESE CABLE SIZES ARE VALID WHEN THE DEVICE IS WITHIN 6 FT DIS TANCE FROM THE POWER SUPPLY THICKER WIRING WILL BE REQUIRED FOR LONGER DISTANCES THINNER WIRES WILL CAUSE OVERHEATING AND EXCESSIVE VOLTAGE DROP SEC 100BRM 100A 2 AWG UP TO SEC 80BRM 80A 4 AWG 6 SEC 60BRM SEC 40BRM UPTO60A 6AWG DISTANCE ENSURE THAT THE AC POWER IS SWITCHED OFF WHEN ANY DEVICE 15 BE ING CONNECTED TO THE POWER SUPPLY DO NOT ALLOW THE ENDS OF THE POSITIVE AND NEGATIVE WIRES TO T
13. OUCH EACH OTHER FUSE REPLACEMENT ENSURE PROPERLY RATED FUSE 250 V 4A IS USED IN EACH OF THE MODULES ENVIRONMENT DO NOT EXPOSE POWER SUPPLY TO RAIN SNOW OR WATER SPRAY DIS ASSEMBLY AND REPAIR THE POWER SUPPLY SHOULD BE DISASSEMBLED OR REPAIRED BY A QUALIFIED TECHNICIAN INCORRECT REASSEMBLY OR REPAIR MAY RE SULT INA RISK OF ELECTRIC SHOCK OR FIRE WHICH MAY RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE DESCRIPTION This is 19 inch 20 height 3 5 Rack Mount Power Supply which converts 120 V 60 Hz AC power into regulated 14 2 V DC 1 At module output delivering up to a maximum of 100 A continuous up to 115 A surge with 5 Base Level PCB Modules There is provision to connect the power supply to an external battery for backup power in the case of an AC power failure and re charge the battery when AC power resumes Voltage at output terminals Load 8 Load will be 13 8V nominal Please see page 7 for explanation APPLICATIONS The unit is designed for the following applications 1 N 1 redundant systems 2 Future power level expansion 3 Uninterrupted DC output when used in conjunction with an external battery backup DESIGN AND PRINCIPLE OF OPERATION The unit is designed using advanced switch mode technology and active load share circuitry for high reliabil ity high efficiency and minimum size and weight It is modular in construction consisting of up to 5 base level PCB modules referred to a
14. TED BY 2 FANS IN CASE ANY OF THE FANS FAILS LIGHT AND SOUND ALARMS WILL BE ACTIVATED IMMEDIATELY SWITCH OFF THE POWER TO THE UNIT TO PREVENT DAMAGE DUE TO OVER HEATING CONNECTION TO AC OUTLET THE POWER SUPPLY SHOULD BE OPERATED ONLY FROM A STANDARD 3 PIN 120 V AC 60 HZ OUTLET WITH PROPER GROUNDING CONNECTION SEC 100BRM MUST BE POWERED FROM A 30A BRANCH CIRCUIT AND SHOULD BE PLUGGED INTO A 30A AC RECEPTACLE WHICH WILL ACCEPT THE 30A NEMA L5 30P PLUG OF THE POWER CORD SEC 80BRM MUST BE POWERED FROM A 20A CIRCUIT AND MUST BE PLUGGED INTO A 20A AC OUTLET WHICH WILL ACCEPT THE 20A NEMA 5 20P PLUG PROVIDED WITH THE POWER CORD SEC 60BRM AND SEC 40BRM MAY BE POWERED FROM A 15 CIRCUIT ALTHOUGH SEC 60BRM amp SEC 40BRM ARE PROVIDED WITH 20A NEMA 5 20P PLUG THESE MAY BE POWERED FROM A 15A BRANCH CIR CUIT IF 20A BRANCH CIRCUIT IS NOT AVAILABLE FOR THIS SITUATION A SEPARATE 15A NEMA 5 15P PLUG HAS BEEN PROVIDED TO REPLACE THE 20A NEMA 5 20P PLUG PROVIDED WITH THE POWER CORD CAUTION PLUG REPLACEMENT SHOULD BE DONE BY A QUALIFIED ELECTRICIAN PLEASE ENSURE PROPER POLARITY OF THE CONNECTIONS AS FOLLOWS L LINE BLACK WIRE N NEUTRAL WHITE WIRE EARTH GROUND GREEN WIRE DO NOT USE EXTENSION CORD UNLESS ABSOLUTELY NECESSARY IF AN EXTENSION CORD MUST BE USED MAKE SURE 1 THE PINS ON THE EXTENSION CORD S PLUG ARE OF THE SAME NUM BER SIZE AND SHAPE AS THOSE OF THE PLUG OF THE POWER SUPPLY CORD NEVER USE AN EXTENSION C
15. ational Condition No of Wire Opto coupler or Parameter High 1 2 Black Collector AC input is available 16 White Emitter 2 12 Collector Fan failure 19 Green Emitter 3 7 Gray Collector PSM 1 Normal 20 Violet Emitter 4 8 Violet Collector PSM 2 Normal 21 Blue Emitter 5 9 Blue Collector PSM 3 Normal 22 Green Emitter 6 10 Green Collector PSM 4 Normal 23 Yellow Emitter 7 11 Yellow Collector PSM 5 Normal 24 Orange Emitter 8 25 Red Voltmeter 13 Black Voltmeter 9 18 Gray Ammeter 6 Blue Ammeter This signal is the voltage across an internal shunt at 0 5 mV per Amp Shunt Ratio is 50 mV 100 A PROTECTIONS SHORT CIRCUIT PROTECTION In the event of a short circuit the PWM controller will be shut down and the output will drop to near 0 V The green LEDs will flash The unit will reset automatically once the short circuit condition is removed CURRENT LIMITING The unit will enter this mode when the load tries to draw more than the limiting values of currents as shown in the specifications Under this condition there will be loss of voltage regulation and the output voltage will drop The PSM STATUS LEDs will however remain illuminated but dimmed When the overload reaches approximately 140A for SEC 100BRM or 112A for SEC 80BRM or 84A for SEC 60BRM or 56A for SEC 40BRM the output voltage will be approximately 2 7V the unit will shut down will enter hiccup mode The PSM status LEDs will start flashin
16. dule example PSM1 PSMS in Fig 2 above does not break the daisy chain However if any of the sandwiched modules example PSM 2 3 4 is removed the daisy chain is broken In this case the unused female socket for the missing sandwiched module s should be shorted by inserting a shorting link to pre vent a break in the daisy chain Fig 3 Unused female socket LI Figure 3 Shorting Link 2 YEAR Limited Warranty This product manufactured by Samlex America Inc the Warrantor is warranted to be free from defects in workmanship and materials under normal use and service This warranty is in effect for 2 years from the date of purchase by the user the Purchaser If the defective product is within the warranty period the Purchaser should contact the place of purchase to obtain a Return Authorization Number The defective part or unit should be returned at the Purchaser s expense to the authorized location A written statement describing the nature of the defect the date of purchase the place of purchase and the Purchaser s name address and telephone number should also be in cluded If upon the Warrantor s examination the defect proves to be the result of defective material or workmanship the equipment will be repaired or replaced at the Warrantor s option without charge and returned to the Purchaser at the Warrantor s expense if within the warranty period No refund of the purchase price will be granted to the Pu
17. e amount of signal picked up from the power supply and also increase the amount of the desired signal 13 The conducted RF noise from these power supplies is limited to the maximum allowable levels by internal filtration The filtered RF noise currents are by passed to the chassis of the power supply The chassis is in turn connected to the earth ground pin of the AC input power cord for Class 1 units Thus the filtered noise currents are intentionally leaked to the earth ground This is termed as the Earth Leakage Current For safety against electric shock this earth leakage current is also required to be limited It will be seen that these two requirements are conflicting NOTE In some cases to prevent electric shock hazard due to abnormal leakage current like in marinas spas hot tubs wet spaces etc the AC outlet circuits receptacles in these areas are served through a GFCI Ground Fault Circuit Interrupter This GFCI is normally set to trip when it senses an earth leakage current gt 5 mA A single GFCI may be serving multiple AC outlet circuits receptacles and therefore will be sensing the sum of all the leakage currents of the devices connected to these As the switching power supplies have intentional leakage current as explained above it may trip a GFCI feeding multiple AC outlet circuits receptacles In such cases disconnect devices connected to the other AC outlet circuits receptacles served by this
18. g and PSM status signal for remote indication will oscil late between High and Low The unit will reset automatically as soon as the overload condition is re moved INPUT SURGE PROTECTION The unit is protected against input voltage surges In case of input spike surge the A C side breaker will trip The 4A fuse on the module will also blow 5 FAN FAILURE WARNING INDICATOR AND ALARM If forced air cooling is stopped due to failure of any one or both the fans the red FAN FAILURE LED will be illuminated and an alarm buzzer will be activated At the same time a High signal will be fed to the opto coupler for signaling fan failure for remote monitoring see Page 5 The unit is required to be switched off immediately as loss of forced air cooling may result in major damage to the unit INSTALLATION AND OPERATION 1 10 11 12 Ensure that the space where the unit is to be installed has adequate air supply for cooling There should be no obstruction on the suction vent slots on the sides of the unit or on the discharge side grilles of the fans on the back of the unit Switch off the on off switch on the front panel Switch off all the D C load s to be connected to this unit Connect the Load and Load at the back of the unit to the D C load s or the DC bus Ensure the wire or bus bar used to connect the load or the D C bus is of proper cross section to carry the desired load current Tighten the screws
19. he voltage at the output terminals LOAD and LOAD will be as follows At no external load Module voltage minus 0 2V At 10A load Module voltage minus 0 4V At loads gt 10A Module voltage minus 0 4V minus 5mV per Amp above 10A Procedure e Switch off the unit and unplug the power cord e The output voltage of each individual power supply module PSM is adjusted one by one starting from the left most module PSM 1 and progressing to the right most module PSM No 5 for SEC 100BRM AC input is connected only to the module being ad justed AC input to the remaining modules is disconnected Remove the AC input connections female quick connect terminals connected to the L and N male tab terminals on the modules Fig 1 from PSM Nos 2 3 4 and 5 Temporarily insulate these female quick connect terminals with insulating tape for safety Now only PSM No 1 can be energized e Switch on the power supply Only PSM No 1 will operate Adjust the output voltage of this module to the desired value with the help of potentiometer VR1 Fig 1 Measure the voltage at the screw terminals S5 and S6 Fig 1 e Switch off the power supply Remove the AC input connection from PSM No 1 Temporar ily insulate these terminals with insulation tape Remove temporary insulation from the AC connectors for PSM 2 and connect them to PSM 2 Now only PSM 2 can energize e Switch on the power supply Only PSM No 2 will operate Adjust the output vo
20. ll result in sparking overheating and consequent damage to the module 4 Each module has independent AC power input wires Locate unused pair of AC input wires Black and white with insulated female quick connect terminals The black wire is required to be connected to the male tab terminal marked L Fig 1 and white wire is required to be connected to the male tab terminal marked N Fig 1 DO NOT CONNECT THESE WIRES TILL STEP 8 BELOW 5 Terminal marked LED2 Fig 1 is used for the front panel LED under PSM Status 1 to 5 and terminal marked LED1 Fig 1 is used for remote indication through the D Sub connector The PSM status output signal from connector LED1 is fed to the associated opto coupler on the small opto coupler PCB Printed Circuit Board amp from there it is fed to the D Sub connector Connection to the opto coupler PCB and on ward to the D Sub connector for remote indication is made using color coded pair of wires for each of the 5 modules Please see the colour code for PSM 1 to 5 under REMOTE MONITORING AND INDICATION on Page 5 An LED holder and a green LED with wire and female quick connect terminal are provided with the new module for connecting to the front panel The vacant hole s for the front panel LEDs are closed with plastic plug s Remove the plastic plug from the vacant hole for the LED under the existing bottom most LED Insert the LED holder in this hole from the outside Insert the green LED from the inside a
21. ltage of this module to the desired value with the help of potentiometer VR1 Fig 1 Measure the voltage at the screw terminals S5 and S6 Fig 1 e Continue to adjust the voltage of the remaining Module Nos 3 4 and 5 individually as explained above making sure that the AC power is connected to only the module being adjusted e After all the modules have been adjusted to the same output voltage connect the AC input back to all the five modules Power on the unit and check that all the 5 PSM Status LEDs are lighted This will con firm that the voltage adjustment has been completed successfully NOTE As explained under Design amp Principle of Operation on page 3 it is likely that the minimum internal preload current for the new value of the output voltage may not be sufficient to provide adequate feedback signal strength resulting in shut down of one or more PSM s when no external load is present The associated PSM Status LED will flash and also the associated signal for remote indication will oscillate between High and Low In such a case apply an external load to increase the feed back signal strength If there is no other defect the PSM s that were shut down will also operate normally INSTALLATION AND REMOVAL OF POWER SUPPLY MODULES NOTE INSTALLATION AND REMOVAL OF POWER SUPPLY MODULES SHOULD BE PERFORMED ONLY BY QUALIFIED PERSONNEL CAUTION Before removing a defective module or installing a new one switch off the 1
22. nd push it till itlocks Connect the female quick connect terminal of the LED to the male quick connect terminal marked LED2 Fig 1 If remote indication is also required then connect the female quick connect terminal of the corresponding colour coded wire for the remote indication connection to the male quick connect terminal marked LED1 Fig 1 6 1 the connected modules operate under forced current share control through a daisy chained SHARE BUS formed by interconnecting each module through the male quick connect terminal marked JUMPI Fig 1 8 2 A wire with 5 female quick connect terminals is provided for the above connection Locate the unused female quick connect terminal s of this wire and connect it to the male quick connect terminal marked JUMP1 Fig 1 7 Use cable ties to secure all loose wiring 8 As explained under OUTPUT VOLTAGE ADJUSTMENT on pages 8 and 9 the output voltage at the indi vidual modules Measured at points S5 amp S6 of the module as shown at Fig 1 on page 17 is required to be set exactly at the same voltage for proper current share control Each module is factory preset at a voltage of 14 2V with the help of potentiometer VR1 Although the optional module SEC 2012MPSB is factory preset at 14 2V it may differ slightly due to tolerance It is therefore necessary to ensure that the voltage of all the individual paralleled modules the existing modules and the additional optional module s is set exactly at
23. pacitor in the front end of the switching power supplies excepting those with power factor correction are notorious for generating power supply harmonics due to the non linear input current waveform The noise is both conducted and radiated through the input power cord and the DC output wiring to the radio Filters are used to limit the noise to acceptable level Switching power supplies are also recipients of radio interference The nor mal operation of the power supply can be disturbed due to RF noise getting coupled into the power supply Thus the power supply may generate exces sive RF noise and lose output voltage regulation due to excessive transmitter energy being coupled through the AC DC lines to the power supply s regu lator feedback path This may be due to antenna being too close or due to the antenna or feed system not radiating properly First check the antenna system SWR Then if necessary relocate either the antenna or the power supply farther apart The receiver may hear the power supply A slowly moving slightly buzzing carrier heard in the receiver may be caused by the antenna being too close As with the transmitter related noise pick up a loose coaxial connector or a broken or a missing ground may aggravate this problem Normally these noises will be below the background or band noise Increase the separation between the power supply and the receiving antenna Use an outdoor an tenna This will reduce th
24. pplied to the unit the feed back signal strength will increase and the PSM s that were shut down will also operate normally Switch the volt amp change over switch to the VOLT position The voltmeter should read 14 V on no load Please see explanation on Page 7 Switch on the D C loads The output voltage on load should be 13 65V to 13 35V Please see explanation on Page 7 Switch the Volt Amp meter switch to AMP position to read the load current Ensure that the load current is within the total rated continuous load of the modules installed OPERATION OF BATTERY BACK UP WARNING THE BATTERY SHOULD BE LOCATED IN A WELL VEN TILATED AREA TO SAFELY DISSIPATE HYDROGEN GAS PRODUCED DURING THE CHARGING PROCESS POSITIVE i BATTERY BUS BAR E l 3 LOAD NEGATIVE BUS BAR R 02 LOAD D1 D2 SCHOTTKY DIODE 30V 180A R1 R2 POWER RESISTOR 0 78 OHM 35W R STATIC LOAD RESISTOR 120 OHM 5W FUGURE A Please refer to the schematic at fig A above Regulated output voltage of 14 2VDC 1 from the modules measured at screw terminals S5 and S6 Fig 1 is fed to the positive and negative DC bus bars and from there to the output terminals LOAD and LOAD through the isolating Schottky Di ode D1 Although the output voltage at the module terminals S5 and S6 Fig 1 or at the common DC bus bar before the Schottky Diode D1 is tightly regulated at the preset value of 14 2VD
25. rchaser unless the Warrantor is un able to remedy the defect after having 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 water immersion No other express warranty is hereby given and there are no warranties which extend beyond those described herein This warranty is expressly in lieu of any other expressed or implied warranties including any implied warranty of merchantability fitness for the ordinary purposes for which such goods are used or fitness for a particular purpose or any other obligations on the part of the Warrantor or its employees and representatives There shall be no responsibility or liability whatsoever on the part of the Warrantor or its em ployees and representatives for injury to any persons or damage to person or persons or dam age to property or loss of income or profit or any other consequential or resulting damage which may be claimed to have been incurred through the use or sale of the equipment includ ing any possible failure of malfunction of the equipment or part thereof The Warrantor assumes no liability for incidental or consequential damages of any kind
26. s PSM Power Supply Module that are connected in parallel with true current sharing Each PSM is a stand alone power supply which delivers up to a maximum of 20 A continuous By equalizing the output currents uniform thermal stress of the individual PSM is ensured which has utmost importance for long term reliability of electronic components The operating principle of the current share mechanism is to measure the output current of each PSM and to be able to modify the output voltages of the PSMs until all the participating PSMs deliver equal output current Typically the output currents of the paral leled PSMs will be within 10 of each other at full output current One of the modules automatically assumes the role of a master and the others operate as slaves Each PSM is required to be interconnected with one another to a common SHARE BUS through a pair of parallel pins marked JUMP 1 and jumper wires Fig 1 and 2 For proper operation of the current share control circuitry a minimum load current is required to flow through each PSM to produce adequate feed back signal This minimum pre load current is provided by the sum of the currents drawn by the fans and by an internal static load resistor connected across the load output termi nals This internal pre load current is kept to the minimum to reduce dissipation NOTE It is likely that due to the drift in the pre set values the minimum internal preload current may not be
27. t up The unit should be switched off immediately and the defective fan should be replaced NEVER LOAD THE UNIT WHEN THERE IS AN AUDIBLE ALARM AND THE FAN FAILURE LED 15 ILLUMINATED The 2 fans are rated for 12 V nominal and are powered from the output voltage of the modules A small Printed Circuit Board PCB located on the right corner towards the back of the unit is used to monitor the fans for abnormal operating conditions viz open circuit or overload condi tion due to obstructed rotor FRONT PANEL CONTROLS AND INDICATORS The following controls and indicators are provided on the front panel 1A POWER ON OFF SWITCH The rocker switch will illuminate when switched on 1B BREAKER A 25A circuit breaker provides protection on the input side against overload 2 VOLTMETER AMMETER A combined voltmeter and ammeter are provided The function can be switched by the Volt Amp switch 3 3 METER CHANGE OVER SWITCH Switches the combined meter between ammeter and voltmeter 4 L E D PSM STATUS 1 to5 During normal operation the green LED of each Power Supply Module PSM will light In case a power supply module PSM fails its corresponding LED will go off LED 1 is for the left most module near the on off switch 5 L E D FAN FAILURE In case of fan failure this red LED lights up and a buzzer is sounded l ATU FAN HA N 1 DC POWER SYSTEM gt faggot 1 000 461 6806 1
28. ted from the chassis As explained at paragraph 5 above the noise currents are filtered to the chassis ground and the chassis ground is connected to the earth ground through the earth ground pin of the AC power outlet receptacle Avoid connecting referencing the DC negative output terminal of the power supply to the earth ground Connect a 1 4 wave length of wire on the negative terminal of the power sup ply Connect one end of the wire to the negative terminal and leave the other end free The wave length corresponds to the wave length of the interfering frequency May not be practical for long wave lengths Formula Wave length Meters 300 frequency in MHz 15 SPECIFICATIONS SEC 40BRM SEC 60BRM SEC 80BRM SEC 100BRM NO OF MODULES 2 3 4 5 INPUT VOLTAGE RANGE 105 125 60 HZ INPUT CURRENT 8A 12A 16A 20A OUTPUT VOLTAGE At terminals L amp L See page 7 e NOMINAL VDC 2 BON e NOLOAD VDC 40 14 gt e FULL LOAD VDC 13 65V 1355V 13 45V 13 35 V OUTPUT REGULATION 1 At module output 55 S6 Fig 1 OUTPUT CURRENT e CONTINUOUS 40A 60A 80A 100A e SURGE 46A 69A 92A 115A OUTPUT CURRENT LIMIT 48A 72A 96A 120A 4 gt OUTPUT RIPPLE PEAK TO PEAK 150mV OUTPUT NOISE PEAK TO PEAK 1V 0 9V 0 8V 0 7V COOLING FORCED AIR 2 FANS OPERATING TEMPERATURE 0TO40C PROTECTIONS e SHORT CIRCUIT YES e CURRENT LIMIT YES e FAN FAILURE LED AND BUZZER e INPUT SURGE SUPRESSION YES FUSE BREA
29. to ensure firm connection In case external battery is required for battery back up connect the positive of the battery to Battery and negative of the battery to Battery See details under operation of the battery back up Plug the unit into the 120 V 60 Hz standard AC outlet The outlet should be rated at 30A for SEC100BRM 20A for SEC 80BRM and 20 15A for SEC 60BRM and SEC 40BRM Switch on the unit by pressing the power on off switch to on position The switch will be illuminated confirming that input power is available A short beep may be generated by the temperature fault alarm circuit on powering on the unit This is normal Please disregard The PSM Status LEDs will light and on signal will be fed to the associated drives of the opto couplers for remote monitoring indication through the 25 pin D sub connector As explained under Design amp Principle of Operation on page 3 a minimum load current is necessary to operate the current share control circuitry of the PSMs It is likely that due to the drift in the pre set values the minimum internal preload current may not be sufficient to provide adequate feedback signal strength resulting in shut down of one or more modules when no external load is present The associated PSM Status LED will flash and also the associated signal for driving the opto couplers for re mote indication will oscillate between on and off conditions As soon as exter nal load is a
30. ttery will be isolated and the load current will once again be supplied by the power supply The discharged battery will recharge through R1 amp R2 R1 amp R2 are in parallel offering a net resistance of 0 39 Ohm NOTE The value of charge limiting resistors is based on a typical 100AH 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 OUTPUT VOLTAGE ADJUSTMENT NOTE The voltages indicated are at no load and are measured at any of the module output pads under S5 and S6 or at the DC bus before the Schottky Diode D1 Parallel Operation Under Forced Current Share Control The output voltage of each module measured at the module output pads under S 5 and S 6 See Fig 1 is factory pre set at 14 2 V A precision multi turn potenti ometer VR1 is provided for fine adjustment of the output voltage of the module The adjustment range is 13 8 V to 14 6 V For the forced current share control to work properly it is important that the output voltage of each module connected in parallel is exactly the same When 2 or more modules are operating in parallel under forced current share control and if the output voltage of any module is below 14 2 V it s current share control circuitry will not function properly and it s LED will start flashing The LEDs of the other modules which are putting out 14 2 V will remain continuously lighted and the output
31. voltage of the common DC bus before the Schottky Diode D1 will be 14 2 V If the output voltage of any module is higher than 14 2 V it s LED will remain continu ously lighted but the LEDs of all the other modules will flash randomly The output voltage of the common DC bus before the Schottky Diodes D1 will read the higher voltage of this module Adjusting the output voltage of the modules at no load NOTE The output voltage is adjusted by multi turn potentiometer VR1 Fig 1 As the adjustment is very fine multiple turns will be required even for small voltage change Turn clockwise for decreasing and anti clockwise for increasing The adjustment range is 13 8V to 14 6V As explained under OPERATION OF BATTERY BACK UP on page 7 although the output voltage at the module terminals S5 and S6 Fig 1 or at the common DC bus before the Schottky Diode D1 is tightly regulated at the preset value of 14 2 V 1 the voltage at the output terminals Load and Load will vary between 14 V at no load to 13 35 V at full load of 100 A due to the forward voltage drop of the isolat ing Schottky Diode D1 and the drop along the DC bus and wiring 8 The output voltage of the paralleled modules or the common DC bus before the Schottky Di odes D1 can be adjusted between 13 8 V and 14 6 V by adjusting the voltage of each module individually as per the following procedure This procedure is explained for SEC 100BRM which has 5 modules T
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