Switch Mode DC Power Supply with Battery

Switch Mode DC Power Supply with Battery
Switch Mode
DC Power
Supply
with Battery
Backup
SEC-1223BBM-CE
Owner's
Manual
Please read this
manual before
installing unit
Owner's Manual | Index
Section 1
Safety Instructions.................................................................. 3
Section 2
Layout, Output Connection & Dimensions ........................... 5
Section 3
Description & Principle of Operation ..................................... 6
Section 4
Protections ........................................................................... 8
Section 5
Installation ......................................................................... 10
SECTION 6
Operation ......................................................................... 13
Section 7
Limiting Electro-Magnetic Interference (EMI) ...................... 15
Section 8
Troubleshooting Guide ........................................................ 18
Section 9
Specifications ...................................................................... 21
Section 10
Warranty ......................................................................... 23
2 | SAMLEX AMERICA INC.
Section 1 | Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important Safety and Operating Instructions. Please read before
using this unit .
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.
!
CAUTION!
Indicates possibility of damage to the equipment in case of non-compliance.
Please read these instructions before installing or operating the unit to prevent personal
injury or damage to the unit.
!
WARNINGS!
1. DO NOT OPEN TO REDUCE RISK OF FIRE OR ELECTRIC SHOCK. THERE ARE NO USER
SERVICEABLE PARTS INSIDE—REFER TO QUALIFIED SERVICE PERSONNEL.
2. The unit should be grounded to reduce the risk of electric shock. It comes with a detachable power cord that has a 2-Pole, 3Wire grounding European CEE-7/7 “Schuko”
plug. The grounding contact of the plug gets connected to the chassis of the unit.
When the power cord is plugged into the corresponding European CEE-7/7 “Schuko”
receptacle in the power outlet, the chassis of the unit is automatically connected to
the Earth Ground through the Equipment Grounding Conductor that is connected
to the grounding contact of the European CEE-7/7 “Schuko” outlet. The power cord
must be plugged into a European CEE-7/7 “Schuko” 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 fit the outlet,
have a proper outlet installed by a qualified electrician. Improper connection can
result in risk of electric shock.
3. It is recommended that you return your power supply to a qualified dealer for any
service or repair. Incorrect assembly may result in electric shock or fire.
4. 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.
5. To reduce risk of damage to electric plug and cord, pull by plug rather than cord
when disconnecting the unit.
6. An extension cord should not be used unless absolutely necessary. If an extension
SAMLEX AMERICA INC. | 3
SECTION 1 | Safety Instructions
cord is used, make sure that it has 2-Pole, 3 wire grounding, European CEE-7/7
“Schuko” configuration with current carrying capacity of at least 10A.
7. Place the unit in an area that will allow air to flow 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.
8. Keep the unit away from moisture and water.
9. NEVER OPERATE TWO OR MORE UNITS IN PARALLEL.
10. 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 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 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 first. Make sure that all the accessories are off so that you do not cause a spark.
CAUTIONS!
1. Please refer to Fig 2.1 at page 5. Please ensure that the battery is connected with correct polarity - Positive of the battery to the “Battery +” terminal (6) and the Negative
of the battery to the “Battery -” terminal (5). 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.
2. Protect the unit against AC line input transients. Use Transient Suppressor in line with
the AC input.
4 | SAMLEX AMERICA INC.
Section 2 | Layout, Output Connection
& Dimensions
SEC-1223BBM-CE
F2
F1
12V BATTERY
12V DC LOAD
BOTTOM VIEW
LEGEND
1.Lighted Power ON /OFF Rocker Switch (Lights Red when ON)
2. AC Power Cord Inlet – Type “IEC 320-C14” (Detachable Power
Cord with “IEC 320-C13” connector on one end and CEE-7/7
“Schuko” 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
Fig. 2.1 Layout and Output Connections
SAMLEX AMERICA INC. | 5
Section 2 | Layout, Output Connection
& Dimensions
SEC-1223BBM-CE
2.5
TOP VIEW
185
180
2.5
240.5
13.5
223
61
4
53.3
7.7
Fig 2.2 Dimensional Drawing
Section 3 | Description & Principle of Operation
DESCRIPTION
SEC-1223BBM-CE is a Switch Mode Power Supply (SMPS), which converts 230 VAC,
50/60 Hz to regulated 13.8VDC ± 0.2V at 23A continuous. It has additional provision for
battery backup with charging in conjunction with external 12V Lead Acid Battery.
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 efficiency, compact and portable
• Protected against short circuit, overload, over voltage and over temperature
• Cooling by temperature controlled fan improves efficiency and prolongs life of the fan
6 | SAMLEX AMERICA INC.
Section 3 | Description & Principle of Operation
PRINCIPLE OF OPERATION
Please refer to the Layout at Fig. 2.1. The unit consists of 2 Sections - Switch Mode Power
Supply (SMPS) Section and Battery Backup and Charging Section. The unit works as a DC
Uninterruptible Power Source (DC UPS) in conjunction with an external 12V, Lead Acid
backup battery. As long as AC input power is available, the unit will put out 13.8 ± 0.2V
at the Load Terminals (3, 4) and provide a maximum continuous load current of 19A to
23A. At the same time, charging current of up to a maximum of 4A (When battery is
completely discharged to Standing Voltage of 11.1V) will be fed through the Battery
Terminals (5, 6) to charge the external battery. The voltage at the Battery Terminals (5,
6) 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 12V 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 battery will be recharged and kept in
charged condition all the time at Float Voltage of 13.8 ± 0.2V (when fully charged).
When operating in DC UPS Battery Backup Mode (external 12V battery is connected),
the unit is capable of providing short-term surge current overload of up to 50A for < 1
sec (external 25A fuse on the load side will not blow as 50A overload occurs for a very
short period of < 1 sec). During this overload of 50A, the Power Supply Section will
provide 25A and the balance 25A will be supplied by the battery and the battery will
discharge at 25A for the period of the surge. During the period of this surge current
overload, the voltage seen by the load will be = (battery voltage – 0.3V± 0.2V).
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
± 0.2VDC at the Load Terminals (3, 4). The maximum overload current will be limited to
25A. Under overload conditions, the output voltage will not be regulated and will drop.
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
SAMLEX AMERICA INC. | 7
Section 3 | Description & Principle of Operation
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 sucks 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.
Section 4 | Protections
NOTE: Please refer to Fig 2.1, page 5 and explanation under heading “Principle of
Operation”, page 7.
OVER LOAD / SHORT CIRCUIT CURRENT PROTECTION
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) and the Battery Terminals (5, 6) 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) will blow and will disconnect the load. If
the overload / short circuit is removed before the external 25A load side Fuse (F2) blows,
the output voltage at the Load / Battery Terminals will automatically recover when the
load current drops to less than 25A.
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) 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
8 | SAMLEX AMERICA INC.
Section 4 | Protections
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) 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) will be around 0.3 ± 0.2V below the voltage at the Battery Terminals (5, 6). External 25A Fuse (F2) 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 flow
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) on the load side will see
170A and the external 25A Fuse (F1) on the battery side will see 145A, the external 25A
load side Fuse (F2) will blow first.
PROTECTION AGAINST REVERSE POLARITY OF BATTERY CONNECTION
In case of reverse polarity of battery connection, internal Diode connected across the
battery output terminals will be forward biased and the external 32V, 25A battery side
Fuse (F1) 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.
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.
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
SAMLEX AMERICA INC. | 9
Section 4 | Protections
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 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.
OVER VOLTAGE PROTECTION
Over voltage protection is provided through the internal PWM controller
Section 5 | Installation
!
WARNINGS!
Please read “Section 1 - Safety Instructions” for safe installation.
NOTE:
Please refer to Fig 2.1, page 5 - Layout & Output Connections
LOCATION, MOUNTING AND SAFETY
The unit is required to be installed in a safe, well-ventilated and dry location. Please see
details given under Section 1 "Safety Instructions". The unit can be mounted horizontally or vertically. When mounting vertically, please ensure that the Output Terminals
are pointing up or down.
AC INPUT CONNECTION
A detachable power cord has been supplied. Connect the power cord to the AC Power
cord Inlet (2). Plug the power cord to the AC outlet. Please ensure that the voltage of
AC input power at the outlet is 230 VAC, 50/60 Hz.
DC OUTPUT CONNECTIONS
The Load Terminals (3,4) and the Battery Terminals (5,6) have 5mm / 0.2” diameter
tubular hole with set screw (#10, 24 TPI, 5/16” long).
For ensuring firm connection under the set screw, 4 pieces of Pin Type of Terminal Lugs
“PTNB10-12” have been provided for crimping to the bare ends of stranded wires for the
load and battery connections. The terminal can accept wire of up to 10 mm2 / AWG #8.
After crimping the Terminal Lugs, use insulating heat shrink tubing or tape to insulate
the bare cylindrical portion of the lug.
10 | SAMLEX AMERICA INC.
Section 5 | Installation
Load Connection: The load is connected to the terminals marked “Load +” (4) and
“Load - ” (3) through 32V, 25A Fuse (F2) (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) and the Negative of the load to the “Load - ” terminal (3).
Battery Connection: The Positive of the battery is connected to the “Battery +” terminal
(6) and the Negative of the battery to the “Battery - ” terminal (5) through 32V, 25A Fuse
(F1) (See details on page 5 under heading “External Fuses on Battery and Load Sides”).
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.
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 below). USE THICKER WIRE OUT THE 2 SIZES CALCULATED BASED ON THE FOLLOWING 2 CONSIDERATIONS:
1. Safety of Conductor Insulation
Current (I) flowing through resistance (R) of conductor produces power loss (I2R) 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
than the temperature rating of conductor insulation will melt / burn the insulation resulting in possibility of electrical shock and fire. The National Electrical Code
specifies maximum current flow (ampacity) through a particular wire size (normally
specified 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 specifies that the ampacity of the
wire should be 1.25 times the maximum current flow. 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.
2. Limiting Voltage Drop along the Length of the Wiring
Current flowing through resistance produces voltage drop. Voltage drop is higher
for higher resistance (longer length and thinner cross section produce higher
SAMLEX AMERICA INC. | 11
Section 5 | Installation
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
Size of Wiring for 2% Voltage Drop
Rated Current
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 flow consideration will be
thicker than AWG #10 as shown in Table 5.1 above and these thicker sizes should be used.
EXTERNAL FUSES ON THE BATTERY AND LOAD SIDES
A battery is an unlimited source of current that can drive thousands of Amperes of current into a short circuit leading to overheating and burning of wiring / circuit components along the path from the battery terminals to the point of short circuit. This can
cause injury and is a fire 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, therefore, 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:
• External Battery Side Fuse (F1) should be LOCATED as close to the battery Positive
post as possible, preferably within 7” of the battery Positive post
• External Load Side Fuse (F2) should be installed as close as possible to the Positive
Load Terminal (4)
For this unit, external fuses must be used for protection against reverse polarity and
short circuit as follows (Please see Fig 2.1, page 5.)
• 32V, 25A fast acting Fuse (F1) in series with the Positive battery wire within 7” from
the battery Positive post. This fuse provides the following protections:
-
Prevents overheating and burning of wiring due to very heavy current fed from the
battery into a short circuit along the length of wiring from the battery to the Battery
Input Terminals (5, 6).
-
Prevents damage to the unit and to the load due to reverse polarity of battery connection
• 32V, 25A fast acting Fuse (F2) in series with the Positive load wire and within 7” of
the Positive Load Terminal (4). This fuse protects against overload and short circuit on
the load side.
12 | SAMLEX AMERICA INC.
Section 6 | Operation
Please refer to Fig 2.1, page 5 - Layout & Output Connections.
!
CAUTION!
If AC input power is not available and a battery has been connected for backup function, 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 battery will get discharged because of the "No
Load Current" drawn by the load.
To protect the battery against deep discharge, please consider using Samlex America, Inc.
Battery Guard Model No: BG-40, which is a 40A, programmable low voltage disconnect
switch to be used in line with the battery.
SWITCHING ON / OFF
Switching ON (Without Battery Backup - No External Battery Unit Operates as a Normal Power Supply):
-
Check that the load has been connected to the Load Terminals (3, 4) and NOT TO THE
BATTERY TERMINALS (5, 6)
-
Switch ON the unit with the help of the Red Power ON / OFF Switch (1). If AC power is
available and the internal AC side fuse is intact, the ON / OFF Switch will be lighted Red
indicating that the Power Supply Section is in ON condition
-
After a few milli sec, 13.8V ± 0.2V will be available at the Load and Battery Terminals
-
Switch ON the load
Switching ON (With Battery Backup - External Battery is Connected):
-
Check that the load has been connected to the Load Terminals (3, 4) through external 25A
Load Side Fuse (F2)
-
Check that the external battery has been connected to the Battery Terminals (5, 6) through
external 25A Battery Side Fuse (F1)
-
Switch ON the unit with the help of the Red Power ON / OFF Switch (1). If AC power is available and the internal AC side fuse is intact, the ON / OFF Switch will be lighted Red indicating that the Power Supply Section is in ON condition
-
After a few milli sec, 13.8V ± 0.2V will be available at the Load Terminals (3, 4) and the
external battery will start charging at current of up to 4A determined by its State of Charge.
The voltage at the Battery Terminals (5,6) will get clamped to the actual terminal voltage of
the battery corresponding to its State of Charge
-
Switch ON the load
-
The Power Supply Section will supply all the current consumed by the load and the external
battery will be maintained in charged condition all the time at Float Voltage of 13.8V ± 0.2V
(when fully charged)
Switching OFF:
-
Switch OFF the load first
-
Switch OFF the unit with the help of the Red Power ON / OFF Switch (1). Red light inside the
ON /OFF switch will switch OFF
SAMLEX AMERICA INC. | 13
Section 6 | Operation
CHARGING AND BACKUP OPERATION
Charging current will be proportional to the discharged state of the battery and is limited to maximum of 4A when the battery is completely discharged (Standing Voltage of
11.4V). The current will taper down from 4A as the battery gets charged and its voltage
rises. When the battery is fully charged, the current will drop down to 0.1% of the Ah
capacity of the battery to compensate for self-discharge. When fully charged, the voltage at the Battery Terminals (5, 6) will be the Float Voltage of 13.8V ± 0.2V.
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 Absorption Voltage is
increased proportionately. This may not be possible with chargers that do not have programmable charging voltages. It is, therefore, recommended that the capacity of the
battery used with this unit should be in the range of 40 to 100Ah which is appropriate
for 4A charging current.
The voltage seen at the Battery Terminals (5, 6) will be the actual terminal voltage of the
battery (assuming no voltage drop in the battery cables) and will be proportional to its
State of Charge. When the battery is fully charged, the voltage at the Battery Terminals
(5, 6) will approach13.8V ± 0.2V.
If AC input power fails, the DC load(s) will be instantaneously transferred to the external
12V backup battery and the battery will start discharging. When the battery is supplying
the load, the voltage seen at the Load Terminals will be 0.3V ± 0.2V less than the voltage
at the Battery Terminals. When AC input power is restored, the DC load will once again
be transferred instantaneously to the Power Supply Section and the external backup
battery will be recharged and kept in charged condition all the time at Float Voltage of
13.8V ± 0.2V.
SURGE POWER CAPABILITY IN DC UPS BATTERY BACKUP MODE
When operating in DC UPS Battery Backup Mode (external 12V battery is connected),
the unit is capable of providing short term surge current of up to 50A for < 1 sec (external 25A fuse on the load side will not blow for this short duration). Maximum 25A
will be provided by the Power Supply Section and balance 25A will be supplied by the
battery. During the period of this short term overload, the voltage seen by the load will
be = (battery voltage – 0.3V± 0.2V).
OPERATION AS NORMAL POWER SUPPLY WITHOUT EXTERNAL BATTERY
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 13.8V
± 0.2VDC at the Load Terminals (3, 4). The maximum overload current will be limited to
25A. Under overload conditions, the output voltage will not be regulated and will drop.
14 | SAMLEX AMERICA INC.
Section 7 | Limiting Electro-Magnetic
Interference (EMI)
!
CAUTION!
This unit generates, uses and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio communications. The unit complies with the Electro Magnetic Compatibility (EMC) Standards detailed
in the Specifications at page 22. However, this does not guarantee that interference will not
occur in a particular installation. If this equipment does cause harmful interference to radio
or television reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the measures recommended in the following paragraphs.
UN-INTENTIONAL RF NOISE GENERATED BY SWITCHED
MODE POWER SUPPLIES (SMPS)
Switched Mode Power Supplies (SMPS) employ high frequency switching (25 KHz in this
unit) and thus, are a source of radio interference, a recipient of radio interference and a
conduit of radio interference. (Older Linear Type, low frequency 50 / 60 Hz transformer
based power supplies do not employ high frequency switching voltages and will be
quieter as compared to SMPS).
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 SMPS (excepting those with Power Factor correction)
generate 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.
FILTRATION OF CONDUCTED NOISE
The conducted RF noise from this SMPS unit is limited to the maximum allowable
levels by internal filtration. The filtered RF noise currents (< few hundred micro Amps)
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”.
EXCESSIVE RF OUTPUT INTERFERENCE BY SMPS DUE TO INCOMING
RF INTERFERENCE WHEN POWERING RADIO TX / RX
SMPS 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.
SAMLEX AMERICA INC. | 15
Section 7 | Limiting Electro-Magnetic
Interference (EMI)
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, this noise 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.
ADDITIONAL GUIDELINES FOR REDUCING RF NOISE
• Use additional appropriate AC Radio Frequency Interference (RFI) Power Line Filter
rated for minimum 10A immediately before the AC input of the power supply. For
example, consider suitability of Model # 6VN1 from Tyco Electronics www.te.com
or similar. Filtered, Ferrite Coated Cord Set 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 resonances at high frequencies,
reducing the conducted and radiated RF noises even further. For example, consider
suitability of EMC Cord “IMU-13” from EMC Eupen www.emceupen.com or similar.
• Use additional appropriate DC radio frequency interference (RFI) power line filter
rated for minimum 30 A immediately after the DC output of the power supply. For
example, consider suitability of 30A filter Model # “FD10EE030” from Curtis Industries www.curtisind.com or similar.
• 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 isolated from
the chassis. As explained earlier, the noise currents are filtered to the chassis of the
unit and the chassis 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 ¼” wavelength 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 wavelength corresponds to the wavelength of the interfering frequency. (May
not be practical for long wave lengths).
[Formula: Wave length (Meters) = 300 / frequency in MHz]
16 | SAMLEX AMERICA INC.
Section 7 | Limiting Electro-Magnetic
Interference (EMI)
COMBINED FILTERED NOISE CURRENTS FROM MULTIPLE SMPS ON A BRANCH
CIRCUIT MAY TRIP GROUND FAULT CIRUIT INTERRUPTER (GFCI)
During malfunction or an accident, the metal chassis of a device may get energized to
unsafe voltage due to internal high voltage section coming in contact with the chassis.
If a person standing on Earth touches this energized chassis, a leakage current
proportional to the person’s skin resistance will flow through the person’s body to
Earth Ground. The leakage current through the body is higher when the skin contact
resistance 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 from the load and will trip and disconnect the
power circuit if the difference is > 5 mA. GFCIs are normally installed in AC Branch
Circuits feeding power outlets in wet areas like marine craft, RVs, spas, hot-tubs,
kitchens, washrooms, etc.
As explained earlier, RF noise filtration circuits in SMPS generate intentional Earth Leakage Current. SMPS are used extensively as DC power sources in modern day electrical
/ electronic devices e.g. Audio / Video / Computing devices, power supplies, battery
chargers etc. A single GFCI outlet / GFCI breaker may be serving multiple SMPS loads
and therefore, will be sensing the sum of all the Earth Leakage Currents and, if the sum
is > 5mA after connecting this unit, the GFCI will trip. In such a case, disconnect other
SMPS based device(s) being served by this GFCI one by one till the net leakage current is
reduced to < 5mA and the GFCI does not trip. Other solution is to power this unit from
a GFCI outlet / GFCI breaker that does not have any SMPS load or power from an outlet
that is not protected by GFCI.
SAMLEX AMERICA INC. | 17
Section 8 | Troubleshooting Guide
OPERATION AS A SIMPLE POWER SUPPLY - ONLY LOAD IS CONNECTED.
NO EXTERNAL BATTERY AND NO BATTERY BACKUP.
Symptom
ON / OFF Switch is ON
• Switch is NOT lighted
• No DC output
Possible Cause
Remedy
No AC power from the
AC outlet
Check AC power is available at the AC
outlet. Breaker feeding the AC outlet may
have tripped.
Internal AC side fuse
is blown
Open the top cover and check the 4A AC
side fuse. Replace if blown.
If the fuse blows again, the input section
is damaged. Please call Tech Support.
ON / OFF Switch is ON
• Switch is lighted
• No DC output
Unit has shut down due to over
temperature – Temperature of
output transformer windings is:
≥ 105°C ± 5°C / 221°F ± 9°F
Check that the fan is running. If not, the
fan / fan control circuit may have been
damaged. Call Tech Support.
Check that the fan suction vents on
the sides of the unit and the discharge
vents on the bottom of the unit are not
blocked.
The unit will reset automatically when the
transformer windings cool down to
≤ 75°C ± 5°C / 167°F ± 9°F
ON / OFF Switch is ON
• Switch is lighted
• DC Output voltage
drops
GFCI outlet / GFCI breaker
supplying AC power to
the unit trips when the
unit is switched ON
If the voltage loses regulation
and drops to < 13.5V, the unit is
overloaded and is in current limit.
The load is trying to draw ≥ the
current limit value of 25A
Reduce the current drawn by the load to
less than the continuous rating of 23A.
If the voltage drop is considerable
with voltage < 2V, the load side
is seeing a short circuit and short
circuit current limited to 25A is
being driven into the short circuit
Switch OFF the load. Remove the short
circuit on the load side.
Additional RF noise currents from
the unit that are filtered to Earth
Ground increase the net Leakage
Current on the GFCI outlet / GFCI
breaker to > 5mA
Switch OFF other SMPS devices operating
from the same GFCI outlet / GFCI breaker
to reduce the net leakage current to <
5mA
Move the unit to another GFCI outlet /
GFCI breaker that has lesser number of
SMPS load(s) or no SMPS load
Power the unit from normal, non GFCI
outlet or from an outlet not protected by
GFCI breaker
18 | SAMLEX AMERICA INC.
Section 8 | Troubleshooting Guide
BATTERY BACKUP OPERATION - EXTERNAL BATTERY IS CONNECTED
Symptom
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 (5, 6) is < 13.8 ±
0.2V and is dropping
• Output voltage at the Load
Terminals (3, 4) is 0.3V ± 0.2V
lower than the Battery Terminals (5, 6) and is dropping
No AC power from the
AC outlet
Check AC power is available at
the AC outlet. Breaker feeding
the AC outlet may have tripped.
Internal AC side fuse of the Power
Supply Section is blown
Open the top cover and check
the 4A AC side fuse. Replace if
blown.
ON / OFF Switch is ON
• Switch IS lighted
• Load is ON and is operating
normally
• Output voltage at the
Battery terminals (5, 6) is
<13.8V ± 0.2V and is dropping
• Output voltage at the Load
Terminals (3, 4) is 0.3 ± 0.2V
lower than the Battery Terminals (5, 6) and is dropping
Power Supply Section of the Unit
has shut down due to over temperature – Temperature of output
transformer windings is
≥ 105°C ± 5°C / 221°F ± 9°F.
ON / OFF Switch is ON
• Switch is lighted
• Load is ON
• Output voltage at the Load
Terminals (3, 4) loses regulation
and drops below 13.8 ± 0.2V
• Output voltage at the Load
Terminals (3, 4) is 0.3 ± 0.2V
lower than the Battery Terminals (5, 6) and is dropping
Power Supply Section is overloaded and is in current limit
condition. The load is trying to
draw excessive current ≥ the current limit value of 25A. The Time
Current Characteristic of the 25A
fuse (F2) in the Load circuit will
determine the allowable value of
overload current > 25A and the
time it can be sustained before
the fuse blows. The allowable
value will be higher for shorter
duration of overload.
If the fuse blows again, the input
section is damaged. Please call
Tech Support.
Check that the fan is running. if
not, the fan / fan control circuit
may have been damaged. Call
Tech Support.
Check that the fan suction vents
on the sides of the unit and the
discharge vents on the bottom of
the unit are not blocked.
The Power Supply Section will
reset automatically when the
transformer windings cool down
to ≤ 75°C ± 5°C / 167°F
± 9°F. During the time the Power
Supply Section is off, the battery
will supply the load and will
discharge during this period.
Remove the cause of overload
Power Supply Section provides 25A
and the balance of current is fed
from the battery and the battery
starts discharging at current =
(Overload current - 25A)
SAMLEX AMERICA INC. | 19
Section 8 | Troubleshooting Guide
Symptom
Possible Cause
Remedy
ON / OFF Switch is ON
• Switch is lighted
• There is no voltage at the at
the load end and the load is
shut down
• Voltage at the Load Terminals
(3, 4) is 13.8 ± 0.2V
• Voltage at Battery Terminals
(5, 6) is lower than the voltage
at the Load terminals and is
≤ 13.8 ± 0.2V
25A Fuse (F2) in the Load circuit is
blown due to:
- Excessive short time overload
current > 25A exceeding the
Time Current Characteristics of
the 25A fuse, or
- Short circuit in the load circuit
Remove the cause of the overload
or short circuit
ON / OFF Switch is ON
• Switch is lighted
• Load is ON
• Voltage at the Load Terminals
(3, 4) is 13.8 ± 0.2V
• Voltage at Battery Terminals
(5, 6) is the same as the Load
Terminals (3, 4)
• Battery backup function does
not operate – Load shuts OFF
when AC power is interrupted
25A Fuse F1 in the battery circuit
is blown due to:
- Reversal of battery input
connections
- Short circuit in the battery
wiring
Check that the polarity of battery
connections is 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
breaker to > 5mA
Switch OFF other SMPS devices
operating from the same GFCI
outlet / GFCI breaker to reduce
the net leakage current to < 5mA.
Check for short circuit in the
battery wiring and correct.
Move the unit to another GFCI
outlet / GFCI breaker that has
lesser number of SMPS load(s) or
no SMPS load.
Power the unit from normal, non
GFCI outlet or from an outlet not
protected by GFCI breaker.
20 | SAMLEX AMERICA INC.
Section 9 | Specifications
SEC-1223BBM-CE
CATEGORY
AC Input
PARAMETER
SPECIFICATION
Input Voltage
230 VAC Nominal (+6% / -10%), 50/60 Hz
Input Current
2.75A @ 230 VAC
Input Current at No Load
105 mA ± 10%
Inrush current at Startup
32A ±5% for 2.4 ms
Output Voltage at Load Terminals 13.8VDC ± 0.2V
Output Voltage at Battery
Terminals (Without battery)
Output Voltage at Battery
Terminals (With battery)
13.8VDC ± 0.2V
Actual battery voltage corresponding to
State of Charge; 13.5V ± 0.2V when battery is fully
charged and floating
Output Voltage Noise and Ripple < 150 mV Peak to Peak
Continuous Output Current at
Load Terminals
DC output Continuous Output Current at
Battery Terminals (Battery
Backup)
Output Current Limit at Load
Terminals
Output Current Limit at Battery
Terminals (Battery Backup)
Peak Efficiency
External Type & Voltage
Backup Battery
Capacity
Protections
19A (With battery backup);
23A (Without battery backup)
Up to 4A (When battery is completely discharged to
Standing Voltage of 11.1V)
- 25A for 100 sec (External 25A fuse will blow)
- Surge > 25A as permitted by Time Current
Characteristics of 25A load side fuse (In Battery
backup Mode)
4A (When battery is completely discharged to
Standing Voltage of 11.4V)
85% ± 5%
Lead Acid, 12V
40Ah to 100 Ah
Short Circuit, Overload
External 25A Fuse will blow
Over Voltage
Regulated by PWM Controller
Over Temperature
(Power Supply Section)
Output of Power Supply Section shuts down when
Power Transformer winding temperature ≥ 105°C ±
5°C / 221°F ± 9°F); Auto reset on cooling down to ≤
75°C ± 5°C / 167°F ± 9°F
Temperature controlled fan. ON when Power
Transformer winding temperature is ≥ 60°C ± 5°C /
140°F ± 9°F; OFF when cools down to ≤ 40°C ± 5°C
/ 104°F ± 9°F
- 5 mm x 20 mm Glass Fuse
- 250V, 4A, Time Delay Type
- Bussmann: “GDC-4”; LittelFuse - “218004”
Cooling Forced Air
Internal AC Side Fuse
Fuses External Battery Side Fuse (By
User)
- 32V, 25 A, Fast Acting
- Within 7” of the Battery Positive Post
External Load Side Fuse (By User) - 32V, 25 A, Fast Acting
- Within 7” from Load Terminal of the unit
SAMLEX AMERICA INC. | 21
Section 9 | Specifications
CATEGORY
PARAMETER
L ow Voltage Directive (LVD) 2006/95/EC and
2014/35/E
ŸŸ IEC 60950-1:2005 (2nd) + A1:2009
ŸŸ EN 60950-1:2006 + A11:2009 + A1:2010 + A12:2011
ŸŸ AS/NZS 60950-1:2011 + A1:2012; ANNEX ZZ
Variations
Electro Magnetic Interference
(EMI)
European Council Directive 2004/108/EC
ŸŸ EN 55022:2010; Class-B
ŸŸ EN 61000-3-2:2006+A1:2009+A2:2009
ŸŸ EN 61000-3-3:2013
ŸŸ AS/NZS CISPR 22 (2009+A1:2010), Class B; (C-TICK)
Electro Magnetic Susceptibility
(EMS)
European Council Directive 2004/108/EC
ŸŸ EN55024:2010
ŸŸ EN61000-4-2:2009
ŸŸ EN61000-4-3:2006+A2:2010
ŸŸ EN61000-4-4:2012
ŸŸ EN61000-4-5:2006
ŸŸ EN61000-4-6:2009
ŸŸ EN61000-4-8:2010
ŸŸ EN61000-4-11:2004
AC Input Connection
- “IEC 320-C14” Inlet Connector on the unit
- Detachable Power Cord with: “IEC 320-C13”
Connector on one end and CEE-7/7 “Schuko”
Plug on the other end
DC Output Connectors for Load
and Battery Connections
Terminal with Tubular Hole - Diameter 5mm / 0.2”
and set screw (#10, 24 TPI, 5/16” long)
Battery wires
Minimum AWG #10 as per NEC Table 310.15(B)(17):
- Ampacity 40A (1.25 times Maximum current
of 25A)
- Conductor temperature rating of 90°C / 194°F
Operating Temperature Range
0°C / 32°F to 30°C / 86°F
COMPLIANCE
Input / Output
Connections
Environmental
SPECIFICATION
Safety
Dimensions (W x D x H)
Dimensions
& Weight
Weight
185 x 240.5 x 61 mm
7.28 x 9.47 x 2.40 in
1.6 kg
3.4 lb
NOTES: 1. A
ll specifications given above are at ambient temperature of 25°C / 77°F unless
specified otherwise.
2. Above specifications are subject to change without notice
22 | SAMLEX AMERICA INC.
SECTION 10 | Warranty
2 Year limited warranty
SEC-1223BBM-CE manufactured by Samlex America, Inc. (the “Warrantor“) is warranted
to be free from defects in workmanship and materials under normal use and service.
The warranty period is 2 years for the United States and Canada, and is in effect from
the date of purchase by the user (the “Purchaser“).
Warranty outside of the United States and Canada is limited to 6 months. For a warranty
claim, 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.
(Contiguous US and Canada only)
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”)
www.samlexamerica.com
SAMLEX AMERICA INC. | 23
Contact
Information
Toll Free Numbers
Ph: 800 561 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
[email protected]
11001-SEC-1223BBM-CE-0616
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