OPEN FRAME DC POWER SUPPLY
COMPONENT POWER MODULE
FOR
N+1 DC POWER SYSTEM
Thank you for purchasing a Samlex power supply
product!
MODEL:
SEC-1024MPSB
Samlex America Inc.
110-17 Fawcett Road
Coquitlam, BC V3K 6V2 Canada
Toll-Free 1-800-561-5885
INSTALLATION & OPERATING MANUAL
SEC-1024MPSB_June2005
Please read this manual before operating your power supply.
Notes :
Attach your original bill of sale here.
•
•
•
•
PROVIDES N+1 REDUNDANCY (2 OR
MORE RUNNING IN PARALLEL)
EXPAND OUTPUT POWER BY ADDING
POWER MODULES
OPERATION STATUS L.E.D.
REMOTE INDICATION OF OPERATION
STATUS
•
OPEN FRAME CONSTRUCTION
•
2 YEAR WARRANTY
•
TOLL FREE TECHNICAL SUPPORT
Date purchased : __________________________
Place of purchase : ________________________
Purchase price : ___________________________
Serial number : ____________________________
16.
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 included.
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
Purchaser, unless the Warrantor is unable 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 employees and representatives for injury
to any persons, or damage to person or persons, or damage 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, including any possible failure of malfunction of
the equipment, or part thereof.
The Warrantor assumes no liability for incidental or consequential damages of any kind.
Samlex America Inc. (the “Warrantor”)
15.
TABLE OF CONTENTS
Topic ...... ............... .............. ....... Page
Important safety instructions .. .......... 1,2
Description and application.... ............. 3
Design and principle of operation......... 3
Cooling ... ............... .............. ............. 3
Layout .... ............... .............. ............. 4
Controls & Monitoring ............ ............. 5
Protections ............. .............. ............. 5
Installation and operation....... ............. 6
Parallel operation.... .............. .......... 7,8
Trouble shooting..... .............. ........ 9,10
Limiting EMI............ .............. .. 10 to 13
Specifications ......... .............. ........... 14
Warranty information ............. ........... 15
Notes:..... ............... .............. ........... 16
IMPORTANT SAFETY INSTRUCTIONS
Please read before using your power supply.
SPECIFICATIONS
INPUT VOLTAGE RANGE
OUTPUT VOLTAGE
CAUTION!
ALL ELECTRICAL INSTALLATIONS MUST
MEET LOCAL AND NATIONAL WIRING
CODES AND SHOULD BE PERFORMED BY A
QUALIFIED ELECTRICIAN.
105 to 125 V AC, 60Hz
(Pre-set)
28V DC
Adjustment
26.8 to 28.5V DC
OUTPUT VOLTAGE REGULATION
1%
OUTPUT CURRENT
CONTINUOUS
10A
SURGE
11.5A
OUTPUT CURRENT LIMIT
12A
OUTPUT RIPPLE
LESS THAN 150mV PEAK TO
PEAK
COOLING:
OUTPUT NOISE
LESS THAN 2V PEAK TO PEAK
If the module is installed in an enclosed case, forced air
cooling should be provided.
COOLING
THROUGH HEAT SINK MOUNTED
ON THE PCB. REQURES FORCED
AIR COOLING.
AC INPUT:
OPERATING TEMPERATURE
0 TO 40OC
PARALLEL OPERATION
YES, ACTIVE CURRENT SHARING
The power supply module should be operated from 120V
AC/60 Hz source with proper earth ground connection.
120V, 60 Hz AC input is fed through quick disconnects
marked “L” & “N”. The pads under holes S1,S3 & S4 (Fig.
1 on page 4), should be connected to earth ground. Color
code for AC input wires is:
NEMA
QUICK DISCONNECT “L”
BLACK
QUICK DISCONNECT “N”
WHITE
PADS UNDER HOLES S1,S3,S4 GREEN
1.
INTERNATIONAL
PROTECTIONS
SHORT CIRCUIT
YES
CURRENT LIMIT
YES
INPUT SURGE SUPRESSION YES
FUSE
250V, 4A, SLOW-BLOW
DIMENSIONS
7.2” X 3.4” X 2.5”
WEIGHT, LBS
1.6
BROWN
BLUE
GREEN / YELLOW STRIPE
14.
OUTPUT CONNECTION:
b.
Use additional appropriate DC radio frequency
interference (RFI) power line filter immediately
after the dc output of the power supply. Recommended: Corcom Inc.(www.cor.com ) “DA” /
“DC” series
c.
Twist the positive and negative wires from the
output of the power supply to the radio
d.
The DC side positive and negative outputs of
these power supplies are isolated 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.
e.
Connect a 1/4” wave length of wire on the
negative terminal of the power supply. 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)
28 VDC is supplied through pads under holes S5& S6.
Always ensure that the positive and negative 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.
Use 14AWG wire to connect any device to the power
supply module. This wire size is valid when the device is
within 4 ft. distance from the power supply module. Thicker
wiring will be required for longer distances.
Thinner wires will cause overheating and excessive
voltage drop.
Ensure that the AC power is switched off when any device
is being connected to the power supply module.
Do not allow the ends of the positive and negative wires to
touch each other
FUSE REPLACEMENT:
Ensure that the fuse is a 250V, 4A slow blow
ENVIRONMENT:
Do not expose power supply module to rain, snow or water
spray.
[ Formula: Wave length (Meters) = 300 /
frequency in MHz
DIS-ASSEMBLY AND REPAIR:
The power supply module should be disassembled or
repaired by a qualified technician. Incorrect reassembly or
repair may result in a risk of electric shock or fire which
may result in personal injury and property damage.
13.
2.
DESCRIPTION:
This is a component power supply module for Samlex N+1
DC power system series SEC-24xxBRM (SEC-2430BRM,
SEC-2440BRM, SEC-2450BRM) It converts 120V , 60 Hz
AC into tightly regulated 28 VDC at 10A continuous. Two or
more of these modules can be operated in parallel with active current sharing.
APPLICATIONS:
This unit is designed for the following applications:
A)
As a component power supply module (PSM) in Samlex N+1 DC Power System Series SEC-24xxBRM.
B)
Independent open frame power supply with active
current sharing for parallel operation.
DESIGN AND PRINCIPLE OF OPERATION:
The power supply module is designed using advanced switch
mode technology and load share circuitry for high reliability,
high efficiency and minimum size and weight. Two or more
power supply modules (referred to as PSM “POWER SUPPLY MODULES”) can be connected for parallel operation
with true current sharing. Each module is a stand alone
power supply which delivers up to a maximum of 10A continuous (11.5A surge). By equalizing the output currents,
(when 2 or more modules are operating in parallel), uniform
thermal stress of the individual modules is ensured which
has utmost importance for long term reliability of electronic
components. The operating principle of the load share
mechanism is to measure the output current of each individual module and to be able to modify the output voltage until
all the participating modules deliver equal output currents.
When connected in parallel, each module is required to be
inter-connected with each other to a common “SHARE BUS”
through a pair of parallel pins marked “JUMP1” and jumper
wires. Typically, the output currents for the paralleled units
will be within 10% of each other at full output current.
COOLING:
Heat generated in the module is dissipated through the heat
sink mounted on the PCB.
When the module is being used as open frame power supply
either singly or in parallel, forced air cooling is required to be
provided to cool the heat sink.
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 > 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 GFCI
6.
a.
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. Recommended: Corcom Inc. ( www.cor.com ) “Q” series.
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
12.
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
antenna. This will reduce the amount of signal
picked up from the power supply and also increase
the amount of the desired signal.
5.
The conducted RF noise from these power supplies
is limited to the maximum allowable levels by internal filtration. The filtered RF noise currents are
bypassed 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.
11.
4.
S5 & S6
L&N
LED1, LED2
JUMP 1
VR1
4.
Layout of the module is shown
below
F1
S1 to S4
Switching power supplies are also recipients of
radio interference. The normal operation of the
power supply 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
properly. First check the antenna system SWR.
Then, if necessary, relocate either the antenna or
the power supply farther apart.
Figure 1—Layout of Power Supply Module
Fuse
Holes for 4 screws to fasten the module (Pads under holes
S1, S3 & S4 should be connected to earth ground)
Pads under these holes provide + and - output connections.
L (line) and N (neutral) terminals for 120V, 60 Hz input power supply wires
Terminal for connecting green L.E.D.(s) for monitoring
Jumper terminal for connecting share BUS wire
Potentiometer for output voltage control
LAYOUT:
3.
CONTROLS AND MONITORING:
NO OUTPUT VOLTAGE, GREEN LED(s) CONNECTED
TO LED1/LED2 ARE FLASHING
OUTPUT VOLTAGE CONTROL: Potentiometer VR1
•
•
is a multi-turn potentiometer for fine adjustment
of the output voltage. It is preset at 28V. It can
adjust the output voltage from 26.8 to 28.5V
•
LED FOR MONITORING STATUS OF OPERATON:
LED 1/ LED2 provide connection for LED for
monitoring the status of operation. In the Samlex
N+1 DC Power System series SEC-24XXBRM,
one green L.E.D. is taken to the front panel indication ”PSM Status”. The second LED connector
is for remote monitoring.
PROTECTIONS:
SHORT CIRCUIT PROTECTION: In the event of a short
circuit, the PWM controller will be shut down and the
output will dip to near 0V. The green LED(s) connected
to LED1/LED2 will flash. The unit will reset automatically
once the short circuit condition is removed.
CURRENT LIMITING: The module will enter this mode
when the load tries to draw more than the limiting value
of 11.5A. Under this condition, there will be loss of
voltage regulation and the output voltage will drop. The
green LED(s) connected to LED1/LED2 will, however,
remain illuminated, but dimmed. The unit will reset
automatically as soon as the overload condition is
removed.
INPUT SURGE PROTECTION: The module is protected against input voltage surges. ( By tripping the
external AC side breaker ).
5.
There is a short circuit on the output side
Switch off the unit. Disconnect the load from the
output terminals. Switch on the unit. If the unit now
operates normally, there is a short circuit in the
external load circuit and should be removed .
If short circuit condition persists even after removal
of external load, switch off the unit and contact technical support.
WHEN TWO OR MORE UNITS ARE OPERATING IN PARALLEL
•
The output voltage of the individual modules is not
the same or the forced share control circuitry of the
module(s) is defective. Adjust the voltages of the
module(s) to the same voltage. If the problem persists, call tech support.
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 ).
2.
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 circuit. The secondary source is
from the bridge rectifier, both rectifier noise and
diode recovery. The AC input rectifier / capacitor 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.
INSTALLATION AND OPERATION - AS COMPO-
TROUBLE SHOOTING
GREEN LED(S) CONNECTED TO LED 1/ LED 2 DOES
NOT LIGHT UP
•
The module has become defective
WHEN TWO OR MORE UNITS ARE OPERATING IN PARALLEL
•
The associated module has become defective. The unit
will still operate normally as the remaining working
module(s) 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 module(s). Reduce the load so
that the maximum load drawn is less than the
combined maximum rated output of the working
module(s).
OUTPUT VOLTAGE DROPS
•
NENT PSM IN SAMLEX N+1 DC POWER SYSTEM SERIES SEC-24XXBRM
If the module is being installed in the Samlex N+1 DC
Power System Series SEC-24XXBRM, read the instructions
in the associated manual of the N+1 DC Power System.
INSTALLATION & OPERATION - AS OPEN FRAME
POWER SUPPLY
•
•
•
•
The module has gone into current limit
WHEN TWO OR MORE UNITS ARE OPERATING IN PARALLEL
•
The unit has gone into current limit as the load being
drawn is more than the combined maximum rating of
the working module(s) 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, connected to LED1/LED2 would extinguish.
Reduce the load drawn to a value less than the
combined maximum rated output of the working
module(s). If the voltage does not rise to the rated
voltage of 28 V, then switch off all the loads. If the
voltage in this condition is also low, switch off the unit
and contact technical support
“L” (Line)
“N” (Neutral)
Earth Ground
•
•
•
•
•
9.
Please refer to Fig. 1 on page 4.
The AC input should be fed through a proper external
switch and breaker based on rated current of each
module at approx. 4A.
Forced air cooling should be provided.
Connect the AC input to quick disconnect terminals
marked “L” (Line) & “N” (Neutral). Pads under holes
S1,S3 & S4 should be connected to Earth Ground.
Color code for wires is:
NEMA
Black
White
Green
INTERNATIONAL
Brown
Blue
Green with Yellow stripe
The output is taken from the pads under holes S5(+)
and S6(-).
Operation status green L.E.D’s are connected to connectors LED1/LED2 (Both the connectors are in parallel. One for local indication and the other for remote
indication.)
Switch on AC power, The green LED’s connected to
LED 1/ LED2 will light.
Output voltage will read 28V. It can be adjusted between 26.8 & 28.5 V by potentiometer marked VR1.
See page 4.
Switch on the DC load. The green LED should remain
lighted.
6.
CAUTION! WHEN 2 OR MORE MODULES ARE
OPERATED IN PARALLEL, THE OUTPUT VOLTAGE
OF EACH MODULE SHOULD BE ADJUSTED TO THE
SAME EXACT VALUE WITH THE HELP OF POTENTIOMETER VR1 ( See Figure 1 on page 4 )
PARALLEL OPERATION (Example: 5 Modules)
PSM 1
PSM 2
1
1
—2
3
1.
2.
3.
PSM 3
1
—2
3
PSM 4
—2
3
PSM 5
1
—2
3
1
—2
3
Female socket terminal of the daisy chain
Male 2 pin terminal marked “Jump 1” on the Power
Supply Module.
PCB ( Printed Circuit Board )
•
Adjust the output voltage of each module individually to the same output voltage.
•
Feed AC input power to the 5 modules through a
common switch and breaker rated for 20A ( 4A
per module x 5 modules = 20A )
•
Connect the positive and negative outputs of each
module in parallel.
•
Connect a 200 ohm 5W power resistor across the
common output terminal to provide a static load.
( When units are operating in parallel, each unit
requires a minimum load for the current share
controller to work properly ).
•
Inter-connect the share bus terminals marked
Jump 1 as shown in Fig. 2 above.
•
Switch on AC power to the modules. Ensure that
green LED’s connected to LED1/LED2 are lighted.
•
Switch on the DC load. All the green LEDs connected to LED1/LED2 should remain lighted.
Fig. 2 - Daisy chaining of share bus jumpers
Fig. 2 above shows an example of 5 modules connected in
parallel to provide 50 Amps.
7.
8.