Model 2000-16-3624 Instruction Manual Power Supply/Battery Charger

Model 2000-16-3624  Instruction Manual Power Supply/Battery Charger
Instruction Manual
Model 2000-16-3624
Power Supply/Battery Charger
September 2015, Rev. 0
Data, drawings, and other material contained herein are proprietary to Cross Technologies, Inc.,
but may be reproduced or duplicated without the prior permission of Cross Technologies, Inc.
for purposes of operating the equipment.
When ordering parts from Cross Technologies, Inc., be sure to include the equipment
model number, equipment serial number, and a description of the part.
CROSS TECHNOLOGIES, INC.
6170 Shiloh Road
Alpharetta, Georgia 30005
(770) 886-8005
FAX (770) 886-7964
Toll Free 888-900-5588
WEB: www.crosstechnologies.com
E-MAIL: info@crosstechnologies.com
INSTRUCTION MANUAL
MODEL 2000-16-3624 Power Supply/Battery Charger
TABLE OF CONTENTS
Warranty
1.0 General
1.1 Equipment Description
1.2 Technical Characteristics
2.0 Installation
2.1 Mechanical
2.2 Top & Side Panels, Inputs, Outputs & Indicators
2.3 Operation
2.4 Alarm Indication
2.5 Connector Pinouts
3.0 Environmental Use Information
PAGE
2
3
3
5
7
7
8
9
10
10
11
WARRANTY - The following warranty applies to all Cross Technologies, Inc. products.
All Cross Technologies, Inc. products are warranted against defective materials and
workmanship for a period of one year after shipment to customer. Cross Technologies,
Inc.’s obligation under this warranty is limited to repairing or, at Cross Technologies, Inc.’s
option, replacing parts, subassemblies, or entire assemblies. Cross Technologies, Inc. shall
not be liable for any special, indirect, or consequential damages. This warranty does not
cover parts or equipment which have been subject to misuse, negligence, or accident by the
customer during use. All shipping costs for warranty repairs will be prepaid by the
customer. There are not other warranties, express or implied, except as stated herein.
CROSS TECHNOLOGIES, INC.
6170 Shiloh Road
Alpharetta, Georgia 30005
(770) 886-8005
FAX (770) 886-7964
Toll Free 888-900-5588
WEB www.crosstechnologies.com
E-MAIL info@crosstechnologies.com
2000-16-3624 Manual_Rev.0
Page 2
09/17/15
MODEL 2000-16-3624 Power Supply/Battery Charger
1.0 General
1.1 Equipment Description
The 2000-16-3624 Power Supply/Battery Charger uses a +10VDC to +36VDC input to provide +24VDC @3A and +12VDC @3A outputs used for
remote terminals. Additionally the power supply will operate from up to 4 BB-2590 type military batteries when DC input power is not available.
The power supply provides all the functionality and safety features of a Level 2 charger and with optional Ethernet will provide Level 3 charger
capabilities. With DC input power applied, the power supply will charge the batteries as needed based on the data collected from the batteries via the
SMBus to a maximum of 8 Amps total charge current. The power supply can be used as a stand alone charger. LED indicators show battery status,
Primary Power Source, +12V and +24VDC Status. The power supply is housed in a 10” X 16” X 1.5” enclosure (connector protrusion not included).
SIDE PANEL (Shown with optional Ethernet)
TOP PANEL
FIGURE 1.1 Top and Side Panels
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1.1 Equipment Description (continued)
DC TO DC
DC IN
+24V@400W
BAT"A "
BAT "B"
BAT" C"
BAT "D"
DUAL
DU AL
DUAL
DUAL
BAT
MNGMT
BAT
MNGMT
BAT
MNGMT
BAT
MNGMT
DC TO DC
+24VDC
+24VDC
DC TO DC
+12VDC
+12VDC
10-36V
SMBus
MICRO
BB -2590
TY PE
FIGURE 1.2
DC Input Connector
Terminal Block
40 A Maximum
2000-16-3624 Manual_Rev.0
BB-2590
TY PE
3A MAX
INDIC ATORS
ETHERNET
(OPTIONAL)
BB-2590
TY PE
2000-16-3624 Power Supply/Battery Charger
Block Diagram
Power Switch
FIGURE 1.3
BB-2590
TY PE
3A MAX
+24 VDC Output
Connector, Molex
2 Pin Female
+12 Output Connector
DB-9 Female
RJ-45 Ethernet
Connector (Optional)
2000-16-3624 Power Supply/Battery Charger
Side Panel
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1.2 Technical Characteristics
TABLE 1.0
2000-16-3624 Power Supply/Battery Charger Equipment Specifications*
DC Input Characteristics
Voltage
+10VDC to +36VDC**
Input Power
400 Watts Maximum (i.e., 40 Amps with +10VDC input)
DC Output Characteristics
Voltage/Current
+12 VDC @ 3 Amps Maximum**
+24 VDC @ 3 Amps Maximum**
Load Regulation
±5%
Power Supply Type
Switcher
Switching Frequency
Various
Battery Charger Characteristics
Number of Chargers
4 Dual
Charger Type
Level 2 “Smart” (Level 3 with Ethernet Option)
Charger Current
8 Amps Maximum Total
Chargeable Battery Type
BB-2590 with SMBus or Compatible
LED Indicators
Power
Green
Alarm
Red (DC Outputs, Thermal, etc.)
Primary Power (2)
Green (DC Input or Battery)
DC Outputs (2)
Green (+24VDC and +12VDC)
Battery SOC Indicators
Green (Flashing = Charging)
61% to 100%
Yellow (Flashing = Charging)
21% to 60%
Red (Flashing = Charging)
0% to 20%
All Off
No SMBus Battery Detected
Physical Characteristics
Size (Excluding Connector Protrusion)
10”W x 16”L x 1.563”D (254 x 406 x 39.7 mm)
Weight
10 lbs. (4.5 kg)
Environmental
Temperature
10˚C - 40˚C
Humidity
< 95%, Non-Condensing
Options
W18
Ethernet with Web Browser & SNMP
W28
Ethernet with TCP/IP, Telnet®
* Specifications subject to change without notice.
** Consult Factory for different Input and Output Voltage Requirements.
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1.2 Technical Characteristics Continued...
TABLE 1.0
2000-16-3624 Power Supply/Battery Charger Equipment Specifications* Continued
I/O Connectors
Mating Connectors
DC Input - 1701692 (Phoenix Contact)
1967456 - (Phoenix Contact 6–20 AWG Wire)
+24VDC Output - Molex 39-30-0020
Molex 39-01-2020 (Contact 39-00-0039)
+12VDC Output - D-Sub 9-pin Female
D-Sub 9-pin Male
Remote On/Off - Amp 6403892
Amp 640426-2 (18 AWG Wire)
Battery - SN0019-5NA-0-0 (5 Key)
Battery - SC-C-179495 (or equivalent)
Ethernet - RJ-45 Female (Optional)
RJ-45 Male (Optional)
* Specifications subject to change without notice.
** Consult Factory for different Input and Output Voltage Requirements.
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2.0 Installation
2.1 Mechanical
Figure 2.0 shows how the 2000-16-3624 is assembled.
+12VDC
DC to
DC
+24VDC
DC to DC Converter
(Charging)
P
Dual
Battery
Charger
Dual
Battery
Charger
Dual
Battery
Charger
Dual
Battery
Charger
FIGURE 2.1 Mechanical Assembly
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2.2 Top & Side Panels, Inputs, Outputs, and Indicators
Figure 2.2 shows the input and output signals and indicators on the top panel.
Power Status
GREEN LED
LED Primary Battery
Source Indicators
Battery
Status RED, GREEN,
YELLOW LEDs
Battery
Status RED, GREEN,
YELLOW LEDs
Battery
Status RED, GREEN,
YELLOW LEDs
Footman Loops
for 1” Straps (4 Sets)
Alarm Status
RED LED
Battery
Status RED, GREEN,
YELLOW LEDs
BB-2590 Battery Connectors (4)
SN0019-5x
FIGURE 2.2 Top Panel Connections and Indicators
Figure 2.3 shows the signals and indicators on the side panel.
DC Input Connector
Terminal Block.
40 A Maximum
+24 VDC Output
Connector, Molex
2 Pin Female
Power Switch
+12 Output Connector
DB-9 Female
+
+
RJ-45 Ethernet
Connector (Optional)
FIGURE 2.3 Side Panel Connections
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2.3 Installation / Operation
2000-16-3624 Power Supply/Battery Charger
1. The power switch is shipped with a jumper to turn on the unit. If a remote power switch is desired,
remove the jumper and connect a remote power switch to the terminals (Open = Off, Closed = On).
Remove connector while making the following connections!
2. Connect the +24VDC and +12VDC Outputs to respective devices.
3. Connect the DC Input to the mating connector with appropriate wire gauge and insert connector into unit.
The DC Input Current is inversely proportional to the Input Voltage (i.e., a +10VDC input can have as
much as 40 Amps of input current, whereas a +20VDC input should have no more than 20 Amps of input
current). Make sure to size the input wire gauge appropriately for your application!
4. Install up to four BB-2590 or equivalent batteries as desired. Batteries are 'Hot Swappable' and can be
added or removed at any time. Use one inch straps (not provided) through the 'Footman loops' to hold
batteries in place. This is critical for mobile applications.
5. Connect the RJ-45 Ethernet jack to your network with appropriate network cable
(Ethernet Option ONLY). Refer to Ethernet insert for detailed operation.
6. Apply power and insert ON/Off Switch jumper and/or turn remote power switch to the ON position.
7. Initial power up begins the unit's self test which includes LED test, DC Output Voltage and Current,
Temperature, Charge voltage etc. After initial power up the Power LED, Primary Power (either DC Input
or Battery), both +12VDC and +24VDC indicators should be illuminated and the Alarm LED should
be off. Battery Status indicators for all compatible batteries installed should also be illuminated according
to their status. Non-compatible batteries will not have any status indicators illuminated but can be used to
supply battery power to the unit.
8. Verify the Power Supply is providing appropriate power to the external devices.
9. Verify any compatible batteries in need of charging are being charged.
10. Should an Alarm condition occur, refer to Table 2.0 for assistance in determining the cause of the error.
11. The Power Supply/Charger has the option to disable charging of one or more batteries. The interior
motherboard contains a four position slide switch (S1) allowing charging to be disabled to one of more
batteries (A-D). Onboard LEDs illuminate when charging is Enabled and will be extinguished if
charging is Disabled. The bottom cover must be removed to access switch S1.
(Continued on page 10...)
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2.3 Installation / Operation, (continued from page 9)
12. The maximum total charge current of the Power Supply/Charger is 8 Amps. In the event that multiple
highly discharged batteries are installed and the total desired charging current is greater than 8 Amps, the
charger will disable charging on one or more batteries as needed (beginning with D, then C etc.) to keep
the charge current below 8 Amps. Charging of the disabled batteries will resume when the power load on
the charger allows.
2.4 Alarm Indications
TABLE 2.0
2000-16-3624 Power Supply/Battery Charger Alarm States
Primary Alarm Indications
+24VDC
Voltage and/or
Current
Alarm
LED
and +24V LED Flash Simultaneously
TABLE 2.0
2000-16-3624
Power
Supply/Battery
ChargerAlarm
Alarm
States
+12VDC Voltage and/or Current Alarm
Alarm LED and +12V LED Flash Simultaneously
Charging Voltage and/or Current Alarm
Alarm Flashes twice then pauses (repeats)
Over Temperature Alarm (Charging Disabled)
Alarm Flashes three times then pauses (repeats)
Thermal Shutdown (All Outputs Disabled)
Alarm Flashes Continuously
2.5 Connector - Side panel, DB-9 female
TABLE 2.1 +12VDC DB-9 Connector Pinouts
Pin
Function
1
No Connection
2
No Connection
3
No Connection
4
+12VDC
5
+12VDC
6
No Connection
7
No Connection
8
Ground (+12VDC Return)
9
Ground (+12VDC Return)
2000-16-3624 Manual_Rev.0
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3.0 Environmental Use Information
A. Reduced Air Flow - Installation of the equipment in an enclosure that limits airflow and therefore
convection cooling will cause the unit to thermally shutdown. The power supply/charger is designed to be
operated at elevated temperatures but must be installed so that air can move in and around its enclosure.
B. Circuit Overloading - Consideration should be given to the connection of the equipment to the output
devices and the effect that overloading of these circuits could have on over current protection and supply
wiring. The +24V and +12V DC outputs are protected with a resettable PTC fuses. Should one or both of
these outputs show a fault condition, remove the output connection(s) and reconnect. If the fault clears and
then reoccurs, check the wiring on the output for shorts, etc.
C. Bottom Cover - The Power Supply/Charger has the option to disable charging of one or more batteries.
The interior motherboard contains a four position slide switch (S1) allowing charging to be disabled to one
of more batteries (A-D). Onboard LEDs illuminate when charging is Enabled and will be extinguished if
charging is Disabled. If the Bottom Cover is removed make sure to tightly reinstall all screws.
No user serviceable parts inside.
2000-16-3624 Manual_Rev.0
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CROSS TECHNOLOGIES, INC.
6170 Shiloh Road
Alpharetta, Georgia 30005
Printed in USA
2000-16-3624 Manual_Rev.0
Page 12
09/17/15
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