KEPCO®
THE POWER SUPPLIER™
OPERATOR’S MANUAL
TBC SERIES
POWER SUPPLY
BATTERY CHARGER POWER SUPPLY WITH RELAY ALARM SIGNALS
KEPCO INC.
An ISO 9001 Company.
TBC SERIES
POWER SUPPLY
ORDER NO. REV. NO.
IMPORTANT NOTES:
1) This manual is valid for the following Model and associated serial numbers:
MODEL SERIAL NO. REV. NO.
2) A Change Page may be included at the end of the manual. All applicable changes and
revision number changes are documented with reference to the equipment serial numbers. Before using this Instruction Manual, check your equipment serial number to identify
your model. If in doubt, contact your nearest Kepco Representative, or the Kepco Documentation Office in New York, (718) 461- 7000, requestin g the correct revision for your p articular model and serial number.
3) The contents of this manual are protected by copyright. Reprod uction of any part can be
made only with the specific written permission of Kepco, Inc.
Data subject to change without notice.
MODEL
©2019, KEPCO, INC
P/N 243-1400
KEPCO, INC. 131-38 SANFORD AVENUE FLUSHING, NY. 11355 U.S.A. TEL (718) 461-7000 FAX (718) 767-1102
email: hq@kepcopower.com World Wide Web: www.kepcopower.com
TABLE OF CONTENTS
1-1 TBC Series Rack Mount Battery Charger Power Supply............................................................................... ii
1-2 TBC Mechanical Outline Drawing .............................................................................................................. 1-5
2-1 TBC Series (Except TBC 24-120M and TBC 48-60M) Front Panel Controls and Indicators ..................... 2-2
2-2 TBC 24-120M and TBC 48-60M Front Panel Controls and Indicators....................................................... 2-2
2-3 TBC Rear Panel............................................................. ............................................................................ 2-4
2-4 AC Input Power Terminal Block, TB3......................................................................................................... 2-5
2-5 Circuit Breaker Locking Plate.................................................................................................................. ... 2-6
2-6 Rack Mounting.......................................................................................................................... ... .............. 2-7
3-1 Local Error Sensing Connections............................................................................................................... 3-2
3-2 Remote Error Sensing Connections........................................................................................................... 3-3
3-3 Suggested Wiring for up to Three TBC Units with Remote Sensing and Remote Control......................... 3-4
LIST OF FIGURES
FIGURE TITLE PAGE
LIST OF TABLES
FIGURE TITLE PAGE
1-1 Float, Equalize, and Overvoltage Protection Specifications .......................................................................1-2
1-2 Model Parameters ......................................................................................................................................1-2
1-3 General Specifications ................................................................................................................................1-3
2-1 Front Panel Controls and Indicators ...........................................................................................................2-1
2-2 TB1 Input/Output Terminal Assignments ....................................................................................................2-3
2-3 TB2 Input/Output Terminal Assignments ....................................................................................................2-3
SECTION PAGE
SECTION 1 - INTRODUCTION
1.1 Scope of Manual ..................................................................................................................................... 1-1
1.2 General Description................................................................................................................................. 1-1
1.3 Specifications.......................................................................................................................................... 1-1
1.4 General Features .................................................................................................................................... 1-1
1.5 Overvoltage Protections and Special Features....................................................................................... 1-4
SECTION 2 - INSTALLATION
2.1 Unpacking and Inspection....................................................................................................................... 2-1
2.2 Terminations, Controls and Indicators ..................................................................................................... 2-1
2.3 AC Source Power Requirements ............................................................................................................ 2-4
2.4 Cooling.................................................................................................................................................... 2-5
2.5 Grounding................................................................................................................................................ 2-5
2.6 Circuit Breaker Locking Plate.................................................................................................................. 2-5
2.7 Rack Panel Mounting.............................................................................................................................. 2-6
SECTION 3 - OPERATING INSTRUCTIONS
3.1 General.................................................................................................................................................... 3-1
3.2 DC (Output) Grounding........................................................................................................................... 3-1
3.3 Load Wire Selection................................................................................................................................ 3-1
3.4 Load Connection, Method 1 (Local Error Sensing) ................................................................................. 3-1
3.5 Load Connection, Method 2 (Remote Error Sensing) ............................................................................. 3-2
3.6 Parallel Operation.................................................................................................................................... 3-3
TBC OPR 071019 i
FIGURE 1-1. TBC SERIES RACK MOUNT BATTERY CHARGER POWER SUPPLY
ii TBC OPR 071019
SECTION 1 - INTRODUCTION
FIGURE 0-1.
1.1 SCOPE OF MANUAL
This manual contains instructions for the installation and operation of the TBC 60-25M Battery
Charger Power Supply manufactured by Kepco, Inc., Flushing, New York, U.S.A.
1.2 GENERAL DESCRIPTION
The Kepco TBC Series of Telecommunications Battery Chargers, hereafter referred to as TBC,
consists of three major groups of Power Supplies. They are used for charging 12, 24, and 48
Volt batteries respectively, and are capable of delivering up to 120 Amps. In addition the TBC
60-25M can charge batteries ranging from 3 to 60 Volts. TBC are designed to Float-Charge
large battery arrays such as those found in telephone operating systems.
A sensing circuit is used to indicate whether current is flowing into or out of the TBC. The internal logic reports Charging Stopped when it senses that the battery is not absorbing current from
the Charger but rather is supplying current back to the TBC. This sensor is very sensitive. It can
respond to a reverse current of less than 50 milliamperes for a Charger capable of delivering up
to 120 Amperes.
1.3 SPECIFICATIONS
Table 1-2 lists specifications for Float, Equalize and Overvoltage Protection for all models. Table
1-2 indicates specifications for parameters that vary for different TBC models; Table 1-3 lists
general specifications that apply to all TBC models.
1.4 GENERAL FEAT URES
• Input Circuit Breaker
• Status Indicators
— Power ON - green LED
— Float Mode - green LED
— Equalize Mode - amber LED (flashing)
— Charging Stopped - red LED
• Meters, 3-1/2 Digit LCD
— Voltmeter (separate connection also provided for remote monitoring)
— Ammeter
• 50/60 Hz Operation
• Current Balance terminal provided for parallel operation
• Equalize Charger Timer built in
— 00.0 -99.9 hours
— Start/Reset pushbuttons
• Logic (TTL) output for status monitoring
—Power ON
— Float/Equalize mode
— Charging Stopped
TBC OPR OPR 071019 1-1
TABLE 1-1. FLOAT, EQUALIZE, AND OVERVOLTAGE PROTECTION SPECIFICATIONS
V
V
N
Nominal
Voltage
Range
F
Float Voltage
(1)
Factory
Set
12V 11.5 - 13.5V 13V 0 - 1.5V 14V 16V
24V 23 - 27V 26V 0 - 3V 28V 34V
48V 47 - 54V 52V 0 - 6V 56V 63V
V
X
Extra
Voltage
Range
VE = VF + V
Equalize
(1)
Voltage
(Factory Set)
X
(2)
V
OVP
Overvoltage
Protection
Level
(3)
(3)
(3)
60V 0 - 60V 60V 0 - 3 63 120% ±7% of V
(1) The upper limits of the range adjustments have a tolerance of ±5%.
(2) The Equalize voltage can not be set higher than the Overvoltage protection level.
(3) For the following models V
TBC 12-100M, TBC 24-25M, TBC 24-50M, TBC 24-100M, TBC 48-12M, TBC 48-25M, and TBC 60-25M. Cycle power
is 120% ±7% of V
OVP
- Latch-style tracking overvoltage protection: TBC 12-50M,
SET
to reset. Setting the TBC to less than 13% below the battery voltage may trigger OVP protection that requires power
cycle to reset.
TABLE 1-2. MODEL PARAMETERS
(2)
SET
(3)
Input Current
@100 -
120V a-c
(Max)
@200 -
240V a-c
Efficiency
@240V a-c
Model
Output Voltage
(Volts d-c)
Nominal Range
Output
Current
(Max)
(Amps d-c)
12 VOLT MODELS
TBC 12-20M 12 11 - 15 22 9 3.7 90% A
TBC 12-50M 12 11 - 15 53 9 3.7 90% A
TBC 12-100M 12 11 - 15 100 18 9 90% A
TBC 12-120M
(3)
12 11.5 - 15 120 22 11 81% A
24 VOLT MODELS
TBC 24-25M 24 23 - 30 26 9 3.7 92% B
TBC 24-50M 24 23 - 30 50 18 9 92% A
TBC 24-60M
(4)
24 23 - 30 60 22 11 83% A
TBC 24-100M 24 23 - 30 100 36 18 91% A
TBC 24-120M
(5)
24 23 - 30 120 44 22 83% A
TBC 24-150M 24 23 - 30 150 54 27 92% A
48 VOLT MODELS
TBC 48-12M 48 47 - 60 13 9 3.7 93% A
TBC 48-25M 48 47 - 60 25 18 9 93% A
TBC 48-30M
(6)
48 47 - 60 30 22 11 84% A
TBC 48-50M 48 47 - 60 50 36 18 84% A
TBC 48-60M
(7)
48 47 - 63 60 44 22 84% B
60 VOLT MODELS
TBC 60-25M 60 2 - 63 25 19.7 14.5 90% A
(1) Size A (Rack mount): 5-1/4H x 19W x 13-1/2D (inches), 133H x 483W x 343D (mm)
Size A (Wall mount): 17H x 19W x 6.6D (inches), 432H x 483W x 168D (mm)
(2) Size B (Rack mount): 8-3/4H x 19W x 15D (inches), 222H x 483W x 381D (mm)
Size B (Wall mount): 15H x 19W x 8-3/4D (inches), 381H x 483W x 222D (mm)
(3) Obsolete - TBC 12-120M replaced by TBC 12-100M.
(4) Obsolete - TBC 24-60M replaced by TBC 24-50M.
(5) Obsolete - TBC 24-120M replaced by TBC 24-100M.
(6) Obsolete - TBC 48-30M replaced by TBC 48-25M.
(7) Obsolete - TBC 48-60M replaced by TBC 48-50M.
Size
(1)
(1)
(1)
(1)
(2)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(1)
Weight
(lbs)
[kilograms]
21 [9.5]
25 [11.4]
33 [15]
18.6 [11.5]
33 [15]
53 [24]
25 [11.4]
29.2 [13.3]
53 [24]
1-2 TBC OPR OPR 071019
SPECIFICATION RATING/DESCRIPTION CONDITION
Input Characteristics
TABLE 1-3. GENERAL SPECIFICATIONS
Input Voltage Nominal: 100 - 120V a-c, 220 - 240V a-c
Single Phase, Wide Range
Range: 85 - 264V a-c
Frequency Nominal: 50 - 60Hz
Range: 47 - 63Hz
Leakage
100 - 120V a-c Input <1.0mA a-c max. UL Method, 50-60Hz
Current
220 - 240V a-c Input <2.0mA a-c max. VDE Method, 50-60Hz, 2 terminal connection
Initial Surge
at Turn-on
100 - 120V a-c Input 20A a-c max. First surge after being off for more than 30
seconds.
220 - 240V a-c Input 40A a-c max.
Startup Time 900mS max.
Holdup Time 30mS max.
EMI FCC Class A
Power Factor 0.99 (typ.) 100V a-c input, rated output.
Output Characteristics
Source Effect typical: 0.8% 115 ±15V a-c, 230 ±30 V a-c
Minimum - Maximum
maximum: 1.6%
Load Effect typical: 0.8% 10 to 100%
(1)
maximum: 1.5%
Temperature
typical: 1.0% 0 to 50°C
Effect
maximum: 2.0%
Combined
typical: 2.0% Source, Load and Temperature effects
Effect
maximum: 4.0%
Time Effect typical: 0.2% 1/2 to 8 hours
maximum: 0.5%
Environmental Characteristics
Temperature Operating: 0 to 50°C
Storage: -30 to 75°C
Humidity 95%, non condensing
Cooling Built-in d-c fans with fan stop sensor
(1)
Isolation 500V d-c, 100MegOhms Output to case:
(1) TBC Models 12-20M, 12-50M, 24-25M, and 48-12M have single fan forced air cooling.
TBC OPR OPR 071019 1-3
1.5 OVERVOLTAGE PROTECTIONS AND SPECIAL FEATURES
The TBC incorporates switching power supplies with power factor correction (PFC). A Control
Board in the TBC controls and monitors critical functions of the TBC Battery Charger. The front
panel contains a main Circuit Breaker, voltage and current meters, status indicators (LED), and
an Equalize Timer control.
The Charger provides remote control connections and monitoring connections for DC output,
ON/OFF, Start/Reset, Equalize Timer, remote voltage sensing, and logi c outputs for status monitoring.
The Charger provides remote control connections and monitoring connections for DC out-put,
ON/OFF, Start/Reset, Equalize Timer, remote voltage sensing, and logi c outputs for status monitoring.
The DC output has factory preset voltage and current limit adjustments.
The TBC has an overvoltage protection circuit that senses the output at the Monitor terminals. It
compares a part of the output voltage to a reference voltage. If an overvoltage occurs, Sensing
Voltage Comparators shut off the oscillator, thereby resulting in zero output power. Similar circuits provide overcurrent and overtemperature protection, re sulting in zer o output power if either
condition is detected. In all cases, if the unit shuts off, the unit must be rest by e ither a) removing
a-c input power and the battery for about 30 seconds and then turning the unit back on again or
b) using the remote control (RC) terminals of TB2 at the rear panel to toggle the unit to OFF,
then ON for immediate reset. For overtemperature, the unit must cool sufficiently for reset to be
effective.
1-4 TBC OPR OPR 071019
FIGURE 1-2. TBC MECHANICAL OUTLINE DRAWING
-4/(-5 #
071019 5
1-5/(1-6 Blank)
SECTION 2 - INSTALLATION
2.1 UNPACKING AND INSPECTION
This instrument has been thoroughly inspected and tested prior to packing and is ready for
operation. After unpacking, inspect for shipping damage before attempting to operate. Perform
the preliminary inspection as outlined in the following paragraph. If any indication of damage is
found, file an immediate claim with the responsible transport service.
2.2 TERMINATIONS, CONTROLS AND INDICATORS
a. Front Panel: See Table 2-1 for a description of front panel controls and indicators.
Refer to Figure 2-1 for all models except TBC 24- 120M and TBC 48-60 M. Refer to Fig ure 2-2 for TBC 24-120M and TBC 48-60M.
TABLE 2-1. FRONT PANEL CONTROLS AND INDICATORS
FIG. 2-1
OR FIG. 2-2
INDEX NO.
1 POWER ON/OFF
2VOLTS,
3AMPS
4EQUALIZE TIME
5START
6 RESET
7 CHARGING STOPPED
8EQUALIZE
9EQUALIZE
10 VOLTAGE ADJUST
11 FLOAT
12 FLOAT
13 POWER ON
14 POWER ON/OFF
NAME FUNCTION
Main AC input power circuit breaker.
circuit breaker
LCD display (2)
LCD display
timer
switch
switch
indicator
adjustment control
indicator
lock
adjustment control
indicator
indicator
Locking Plate
3-1/2 digit LCD meter for reading voltage.
3-1/2 digit LCD meter for reading current.
0.1 to 99.9 hour timer that can be set to establish the duration of the Equalize
cycle.
Pressing START button starts the EQUALIZE TIME timer as the Equalize mode
begins.
Pressing RESET button resets the EQUALIZE TIME timer as the TBC returns to
the Float mode.
Red LED to indicate that the TBC has stopped charging.
Screwdriver adjustment of equalize voltage.
Amber LED that flashes when the TBC is in the Equalize mode (high rate of
charging).
A sliding plate behind the panel allows access to the Float and Equalize voltage
controls. For precise settings of these controls refer to the battery's manufacturer.
Screwdriver adjustment of float voltage.
Green LED to indicate when the TBC is in the Float mode (slow rate of charging).
Green LED power on indicator.
Prevents accidental shutoff of TBC. See PAR. ?? for details.
TBC OPR 071019 2-1
FIGURE 2-1. TBC SERIES (EXCEPT TBC 24-120M AND TBC 48-60M)
FRONT PANEL CONTROLS AND INDICATORS
FIGURE 2-2. TBC 24-120M AND TBC 48-60M FRONT PANEL CONTROLS
AND INDICATORS
b. Rear Panel: The TBC has two output power terminals for connecting to the battery and/
or load. It also has two terminal blocks, TB1 and TB2. (see Tables 2-2 and 2-3 for a
description of TB1 and TB2 terminals, respectively. Refer to Figure 2-3 for terminal locations.
2-2 TBC OPR 071019
TABLE 2-2. TB1 INPUT/OUTPUT TERMINAL ASSIGNMENTS
TERMINAL NO. NAME DESCRIPTION OR FUNCTION
1 Control With a jumper between these terminals and the battery connected, the TBC Con2ON/OFF
trol Board will remain ON even if the AC Circuit Breaker is OFF. With the jumper
removed the Control Board will go OFF if the AC Circuit Breaker is OFF.
3 Meter (+) This terminal provides an outside contact point from the positive side of the LCD
voltmeter for remote monitoring of the output voltage.
4+S
This terminal is the positive Remote Sensing terminal for the TBC output voltage.
(Sense)
5+M
(Monitor)
6–M
(Monitor)
7–S
This terminal is connected to the positive output terminal of the TBC Battery Charger and is used for Local Sensing.
This terminal is connected to the negative output terminal of the TBC Battery
Charger and is used for Local Sensing.
This terminal is the negative Remote Sensing terminal for the TBC output voltage.
(Sense)
8 Meter (–) This terminal provides an outside contact point from the negative side of the LCD
voltmeter for remote monitoring of the output voltage.
9CB
(Current Balance)
This terminal is used when two or three TBC units (except for the TBC 12-20M,
which doesn't require Current Balance) are connected in parallel (consult the factory for details).
10 Common This terminal is logic ground.
TABLE 2-3. TB2 INPUT/OUTPUT TERMINAL ASSIGNMENTS
TERMINAL NO. NAME DESCRIPTION OR FUNCTION
1+RC
(Remote Control)
2–RC
(Remote Control)
3 Power On Power On Output Flag. A logic high at this terminal (with respect to Common)
4 Charging Stopped Charging Stopped Output Flag. A logic low at this terminal (with respect to Com-
5 Float/Equalize Float/Equalize Output Flag. A logic high at this terminal indicates that the TBC is
6 Start Start Input Command. A short circuit condition (provided by a computer low signal
7 +5 Volts +5 Volts d-c
8 Reset A short circuit condition (provided by a computer low signal or momentarily clos-
9 50/60Hz A jumper between this terminal and Common sets up the TBC for 60Hz input
10 Common This terminal is logic ground.
Remote Control ON/OFF Input Command. An open (logic high) between the +RC
and -RC terminals will turn OFF the TBC. A short circuit (or logic low) between
these two terminals will return the TBC to operation. Logic high is between 2.4V
and 24V d-c; logic low is between 0V and 0.4V d-c. When high, this terminal can
sink 1.0 rnA maximum; when low this terminal can source 1.6rnA maximum.
indicates that AC input power is ON. A logic low indicates that AC input power is
OFF.
mon) indicates that the battery voltage is equal to or greater than the Power Supply voltage and that the battery has been charged. A logic high indicates that the
Power Supply voltage is higher than the battery voltage and that the battery is
being charged
in the Float (low charging rate) mode. A logic low at this terminal with respect to
Common indicates that the TBC is in the Equalize (high charging rate) mode.
or momentarily closing a switch) at this terminal with respect to Common starts
the TBC timer and the TBC goes into the Equalize mode.
ing a switch) at this terminal with respect to Common resets the Equalize Timer
and the TBC goes back to the Float mode.
power operation. With jumper removed the TBC is set for 50Hz input power operation.
TBC OPR 071019 2-3
FIGURE 2-3. TBC REAR PANEL
2.3 AC SOURCE POW ER REQU IREMENTS
The TBC Battery Charger Power Supply is supplied for operation on a single phase line with a-c
input voltage between 100V and 250V a-c nominal (universal a-c input). The circuit breaker
remains effective at all input voltages.
WARNING: Input current may be hazardous. Refer to Table 1-2 for input current specifi-
cations and ensure source power is off and TBC Power ON/OFF is set to OF F
before proceeding.
a. Remove the four screws from the small panel located on the right side of the TBC Bat-
tery Charger rear panel.
b. Insert the AC power line through the hole in the panel; tighten the cable clamp and con-
nect the line, neutral and ground wires to their respective terminals on the Terminal
Block (see Figure 2-4).
c. Fasten the panel in place on the TBC Battery Charger rear panel.
2-4 TBC OPR 071019
2.4 COOLING
!
The power transistors and rectifiers in the TBC Battery Charger Power Supply are maintained
within their operating temperature range by means of special heat sink assemblies, cooled by
internal fans.
CAUTION: SIDE PANEL OPENINGS AND THE TOP OF THE CASE MUST BE KEPT
Periodic cleaning of the interior of the Power Supply is recommended. If the TBC unit is rack
mounted, or installed in confined spaces, care must be taken that the ambient temperature (the
temperature immediately surrounding the Power Supply) does not rise above the limit specified
(refer to Table 1-3).
2.5 GROUNDING WARNING: For safety reasons it is imperative that the chassis of the power supply be
a. Terminal Block TB3 on the Chassis Assembly has three terminals: Ground, Neutral and
High. The Ground terminal is a chassis ground, and is not the logic ground, nor the
Common found on PC Board 1 and pin 10 of Terminal Blocks 1 and 2 (see Figure 2-3).
FIGURE 2-4. AC INPUT POWER TERMINAL BLOCK, TB3
CLEAR FROM OBSTRUCTIONS TO ENSURE PROPER AIR CIRCULATION.
returned to AC ground with a separate lead. A grounding terminal is provided (on Terminal Block TB3) for this purpose.
b. Isolation From Ground. The DC output is isolated from the AC source and from any
direct connection to chassis or ground. The maximum output voltage that can be supported between either output terminals and ground or chassis is 500 V d-c. Eith er side of
the output may be connected to chassis or Earth ground
2.6 CIRCUIT BREA KER LOCKING PLATE
A locking Plate for the Circuit Breaker is provided to prevent accidental turn OFF of the TBC
unit. It does not affect the circuit breaker tripping action in the event of over load.
TBC OPR 071019 2-5
To release the circuit breaker locking plate loosen the two knurled head screws (6-32 x 1/2) and
slide the locking plate to the right (see Figure 2-5A). For mo dels TBC 24- 120M and TBC 48-60M
slide the locking plate down (see Figure 2-5B).
FIGURE 2-5. CIRCUIT BREAKER LOCKING PLATE
2.7 RACK PANEL MOUNTING
A kit that contains two handles (each o ne with two ferrule mounts) and two flanges (ear s) for
rack mounting is provided with the TBC. Four screws (flat head 10-32 x 1/2, 100 degrees countersink); six screws (truss head, phillips 10-32 x 3/8, black); and six Internal lockwashers (no.
10) are also included. The mounting flanges (ears) for mounting the TBC in a rack can be
installed in either position 1 or position 2 with three screws (Truss Head Phillips 10-32 x 3/8
Black); and three Internal Locking washers, No. 10 (see Figure 2-5). Position 1 is for regular
front panel rack mounting, and position 2 is for rack mounting with part [5 inches ( 127)] of the
TBC Battery Charger extended beyond the front of the rack. Install one mounting Ear on each
side of the TBC unit.
2-6 TBC OPR 071019
FIGURE 2-6. RACK MOUNTING
TBC OPR 071019 2-7/(2-8 Blank)
SECTION 3 - OPERATING INSTRUCTIONS
3.1 GENERAL
Interconnections between a stabilized Battery Charger Power Supply, and its load are as critical
as the interface between other types of electronic equipment. If optimum performance is
expected, certain rules for the intercon nections must be observed by the user. These rules are
described in detail in the following paragraphs.
3.2 DC (OUTPUT) GROU NDIN G
Connections between the Battery Charger Power Supply and the load Goad and sensing connections) may, despite all precautions such as shielding, twisting of wire-pairs, etc., “pick-up”
radiated noise of a wide frequency spectrum. To minimize these undesired effects, one side of
the Battery Charger Power Supply output/load circuit must be grounded.
Successful DC grounding depends on careful analysis of the individual situation and only general guide lines can be provided here. One of the ma jor points, however, is to avoid GROUND
LOOPS. Ground loops are created when two (or more) points are groun ded along the output circuit. Due to the wire impedance between the grounded pOints, a noise voltage is developed
which is superimposed on the load. The only way to avoid ground loop s is to inve stigate the ou tput circuit (including the connected load) with an ohmmeter, for any resistance to ground. A single DC ground point can be selected only if the output circuit is completely isolated. A single
point is selected along the Power Supply output/load circuit and this point is returned to ground
with a single wire. The exact location of this “best” DC ground-point is entirely dependent on the
application at hand. For single, isolated loads, the DC ground-pOint may be located directly at
one of the output terminals of the Power Supply which may be connected to ground. If Error
Sensing is employed, DC ground can be established at the remote load. In case of an internally
grounded load, the DC ground is automatically established directly at the load.
3.3 LOAD WIRE SELECTION
A realistic model for a voltage stabilized Battery Charger Power Supply must, for example,
include a series resistance, representing a small DC and low frequency source impedance; in
series with an inductance, representing the source impedance at higher frequencies. This is
because of the variation in the equivalent characteristic output circuit impedance as the frequency changes. Load wire selection should be made with those facts in mind. The load wire
size should not only be selected for minimum voltage drop (Error Sensing, as discussed below,
will take care of that), but also the series inductance of the load wire must be kept as small as
possible compared to the source inductance of the Battery Charger Power Supply (Error Sensing cannot compensate for this).
3.4 LOAD CONNECTION, METHOD 1 (LOCAL ERROR SENSING)
The most basic Battery Charger Power Supply interconnection for maintaining Batteries connected across a load consists of 2-wire connection from the rear output terminals. The load
leads should be tightly twisted to reduce “pick-up” from stray magnetic fields.
Figure 3-1 shows the correct and incorrect methods of connecting single and multiple loads with
local sensing. Remote Sensing should be used for the most critical load (see PAR. 3.5). Local
error sensing links must be connected with the proper polarity +S to +M and –S to –M. The TBC
Battery Charger Power Supplies are shipped with links (jumpers) that connect the Sensing terminals directly to the Monitor terminals. These links should be removed when remote sensing is
employed.
TBC OPR 071019 3-1
FIGURE 3-1. LOCAL ERROR SENSING CONNECTIONS
3.5 LOAD CONNECTION, METHOD 2 (REMOTE ERROR SENSING)
To avoid excessive output effects at remote loads, re mote error sensing mu st be used. The links
between the +S and + M terminals and between the -S and -M terminals must be removed. Use
a twisted, shielded pair of wires from the Sensing Terminals directly to the load to compensate
for load wire voltage drops. Observe polarities: The negative Sensing wire must go to the negative load wire, and the positive Sensing wire goes to the positive load wire.
The Remote Sensing terminals must be connected to their respective output terminals, either at
the load or at the TBC output; otherwise the TBC will not operate properly. Connecting the +S
and -S terminals directly to the + and – load automatically compensates for voltage drops in the
connecting cables of up to a maximum of 0.40 Volts per cable. Figure 3-2 shows the T BC connected to a battery and multiple loads using remote sensing.
3-2 TBC OPR 071019
FIGURE 3-2. REMOTE ERROR SENSING CONNECTIONS
3.6 PARALLEL OPERATION
Up to three identical TBC Battery Charger Power Supplies can be connected in parallel operation, except for models TBC 48-60M and TBC 24-120M, which have two power supplies in parallel that are built into the units. For the TBC 48-60M or TBC 24-1 20M only one addit ional TBC
unit can be connected in parallel. For parallel operation it is necessary to connect the Current
Balance terminals together (terminal 9 on TB1) for all the TBC units in operation (see Figure 2-
3).
NOTE: To operate up to three TBC Battery Charger Power Supply units in parallel, set the
desired output voltages, at the load, for each TBC battery charger. Remove the links between
the + Sense and + Monitor Terminals and between the -Sense and -Monitor Terminals for each
TBC Battery Charger. Connect TB1 and TB3 for all the TBC units as indicated in Figure 3-2.
This diagram is not valid for the TBC 24-120M and TBC 48-60M since these units already have
two Power Supplies in parallel that are built in to them. Therefore only one other TBC Battery
Charger can be placed in parallel with either one of these two models.
TBC OPR 071019 3-3
FIGURE 3-3. SUGGESTED WIRING FOR UP TO THREE TBC UNITS WITH
REMOTE SENSING AND REMOTE CONTROL
3-4 TBC OPR 071019
Loading...