Samlex America SEC-100BRM User Manual

EXPANDABLE DC POWER SUPPLY

N+1 DC Power System

with Battery Backup / Charging Function

MODELS : SEC-40BRM SEC-60BRM SEC-80BRM SEC-100BRM

INSTALLATION & OPERATING MANUAL

Please read this manual before operating your power supply.

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PROVIDES N + 1 REDUNDANCY

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ALLOWS CONNECTION OF EXTERNAL BATTERIES FOR BACKUP

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EXPAND OUTPUT POWER BY ADDING POWER MODULES

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UP TO 100 AMPS CONTINUOUS POWER

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VOLT / AMPERE METER

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OPERATION STATUS L.E.D.

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FAN FAILURE ALARM AND WARNING L.E.D.

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REMOTE MONITORING AND INDICATION

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19” RACK MOUNT

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2 YEAR WARRANTY / TOLL FREE TECHNICAL SUPPORT

TABLE OF CONTENTS

Topic Page

Important safety instructions 1,2

Description and application 3

Design and principle of operation 3

Cooling and warning for fan failure 3

Front panel controls and indicators 4

Rear panel controls 4,5

Protections 5

Installation and operation 6

Operation of battery back-up 7

Output voltage adjustment 8,9

Installation and removal of modules 9,10

Trouble shooting 11,12

Limiting electromagnetic interference 13,14,15

Specifications 16

Appendix : Figures 1 to 3 17,18

Warranty information 19

Notes 20

IMPORTANT SAFETY INSTRUCTIONS

Please read before using your power supply.

CAUTION !

ALL ELECTRICAL INSTALLATIONS MUST MEET LOCAL AND NATIONAL WIRING CODES AND SHOULD BE PERFORMED BY A QUALIFIED ELECTRICIAN

OPERATION OF COOLING FAN

THE HEAT PRODUCED IS EXTRACTED BY 2 FANS. IN CASE ANY OF THE FANS FAILS, LIGHT AND SOUND ALARMS WILL BE ACTIVATED. IMMEDIATELY

SWITCH OFF

THE POWER TO THE UNIT TO PREVENT DAMAGE DUE TO OVER

HEATING

CONNECTION TO AC OUTLET

THE POWER SUPPLY SHOULD BE OPERATED ONLY FROM A STANDARD 3 PIN 120 V AC/ 60 HZ OUTLET WITH PROPER GROUNDING CONNECTION.

SEC-100BRM MUST BE POWERED FROM A 30A BRANCH CIRCUIT AND

SHOULD BE PLUGGED INTO A 30A AC RECEPTACLE WHICH WILL ACCEPT

THE 30A NEMA L5-30P PLUG OF THE POWER CORD. SEC-80BRM MUST BE

POWERED FROM A 20A CIRCUIT AND MUST BE PLUGGED INTO A 20A AC OUTLET WHICH WILL ACCEPT THE 20A NEMA 5-20P PLUG PROVIDED WITH

THE POWER CORD. SEC-60BRM AND SEC-40BRM MAY BE POWERED FROM

A 15A CIRCUIT. ALTHOUGH SEC-60BRM & SEC-40BRM ARE PROVIDED WITH 20A, NEMA 5-20P PLUG, THESE MAY BE POWERED FROM A 15A BRANCH CIRCUIT IF 20A BRANCH CIRCUIT IS NOT AVAILABLE. FOR THIS SITUATION, A SEPARATE 15A, NEMA 5-15P PLUG HAS BEEN PROVIDED TO REPLACE THE 20A, NEMA 5-20P PLUG PROVIDED WITH THE POWER CORD.

CAUTION !

ELECTRICIAN. PLEASE ENSURE PROPER POLARITY OF THE CONNECTIONS AS FOLLOWS :

“ L ” LINE BLACK WIRE “ N ” NEUTRAL WHITE WIRE EARTH GROUND GREEN WIRE

PLUG REPLACEMENT SHOULD BE DONE BY A QUALIFIED

DO NOT USE EXTENSION CORD UNLESS ABSOLUTELY NECESSARY. IF AN EXTENSION CORD MUST BE USED , MAKE SURE :

1. THE PINS ON THE EXTENSION CORD'S PLUG ARE OF THE SAME NUMBER, SIZE AND SHAPE AS THOSE OF THE PLUG OF THE POWER SUPPLY CORD. NEVER USE AN EXTENSION CORD WITH A 2 PIN PLUG ( THERE WILL BE NO GROUNDING CONNECTION IN THIS TYPE OF PLUG WHICH IS A SHOCK AND FIRE HAZARD )

2. THE EXTENSION CORD WIRE SIZE SHOULD BE MINIMUM 12 AWG, 20 A.

LOAD AND BATTERY CONNECTIONS

THE LOAD & BATTERY TERMINALS ON THE POWER SUPPLY HAVE A TUBULAR HOLE OF DIAMETER 8mm (0.31”) WITH A SET SCREW.

ALWAYS ENSURE THAT THE CONNECTIONS ARE SECURE AND THE SCREWS ARE TIGHTENED PROPERLY.

LOOSELY TIGHTENED CONNECTIONS RESULT IN EXCESSIVE VOLTAGE DROP AND MAY CAUSE OVERHEATED WIRES AND MELTED INSULATION.

THE ENDS OF THE CABLES TO BE CONNECTED TO THE LOAD AND BATTERY TERMINALS ON THE POWER SUPPLY SHOULD HAVE PIN TYPE OF CONNEC-

TOR FOR MAKING A FIRM CONNCECTON. 4 PIECES OF PIN TYPE CONNEC-

TORS ARE ENCLOSED WITH THE POWER SUPPLY. CRIMP THESE TO THE ENDS OF THE CABLES.

USE MULTI STRANDED WELDING TYPE CABLE OR BATTERY CABLE (NEOPRENE SYNTHETIC INSULATION, 90 AS INDICATED BELOW, TO CONNECT ANY DEVICE TO THE POWER SUPPLY. THESE CABLE SIZES ARE VALID WHEN THE DEVICE IS WITHIN 6 FT. DIS-

TANCE FROM THE POWER SUPPLY. THICKER WIRING WILL BE REQUIRED

FOR LONGER DISTANCES. THINNER WIRES WILL CAUSE OVERHEATING AND EXCESSIVE VOLTAGE DROP :

C). USE PROPER SIZE OF CABLE,

SEC-100BRM 100 A # 2 AWG | UP TO SEC-80BRM 80 A # 4 AWG | 6’ SEC-60BRM/SEC-40BRM UP TO 60 A # 6 AWG | DISTANCE

ENSURE THAT THE AC POWER IS SWITCHED OFF WHEN ANY DEVICE IS BEING CONNECTED TO THE POWER SUPPLY.

DO NOT ALLOW THE ENDS OF THE POSITIVE AND NEGATIVE WIRES TO TOUCH EACH OTHER.

FUSE REPLACEMENT

ENSURE PROPERLY RATED FUSE ( 250 V, 4A ) IS USED IN EACH OF THE MODULES.

ENVIRONMENT

DO NOT EXPOSE POWER SUPPLY TO RAIN, SNOW OR WATER SPRAY

DIS-ASSEMBLY AND REPAIR

THE POWER SUPPLY SHOULD BE DISASSEMBLED OR REPAIRED BY A QUALIFIED TECHNICIAN. INCORRECT REASSEMBLY OR REPAIR MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE WHICH MAY RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE

DESCRIPTION

This is a 19 inch, 2U height (3.5”) Rack Mount Power Supply which converts 120 V , 60 Hz. AC power into regulated 14.2 V DC , +/- 1% (At module output*) delivering up to a maximum of 100 A continuous ( up to 115 A surge ) with 5 Base Level PCB Modules. There is provision to connect the power supply to an external battery for backup power in the case of an AC power failure and re-charge the battery when AC power resumes.

Voltage at output terminals Load+ & Load- will be 13.8V nominal (Please see page 7 for explanation.)

APPLICATIONS

The unit is designed for the following applications:

1. N+1 redundant systems

2. Future power level expansion

3. Uninterrupted DC output when used in conjunction with an external battery backup.

DESIGN AND PRINCIPLE OF OPERATION

The unit is designed using advanced switch-mode technology and active load share circuitry for high reliability, high efficiency and minimum size and weight. It is modular in construction consisting of up to 5 base level PCB modules (referred to as “PSM” – Power Supply Module) that are connected in parallel with true current sharing. Each PSM is a stand alone power supply which delivers up to a maximum of 20 A continuous. By equalizing the output currents, uniform thermal stress of the individual PSM is ensured which has utmost importance for long term reliability of electronic components. The operating principle of the current share mechanism is to measure the output current of each PSM and to be able to modify the output voltages of the PSMs until all the participating PSMs deliver equal output current. Typically, the output currents of the paralleled PSMs will be within 10% of each other at full output current. One of the modules automatically assumes the role of a master and the others operate as slaves. Each PSM is required to be interconnected with one another to a common “SHARE BUS” through a pair of parallel pins marked “JUMP 1” and jumper wires ( Fig. 1 and 2).

For proper operation of the current share control circuitry, a minimum load current is required to flow through each PSM to produce adequate feed back signal. This minimum pre-load current is provided by the sum of the currents drawn by the fans and by an internal static load resistor connected across the load output terminals. This internal pre-load current* is kept to the minimum to reduce dissipation.

* NOTE: It is likely that due to the drift in the pre-set values, the minimum internal preload current may not be sufficient to provide adequate feedback signal strength resulting in shut down of one or more modules when no external load is present (The associated PSM Status LED will flash and also, the associated signal for remote indication will oscillate between High and Low). As soon as external load is applied to the unit, the feed back signal strength will increase and the PSM(s) that were shut down will also operate normally.

The output is delivered through an isolating Schottky diode to enable connection of external battery for uninterrupted DC power output. The external backup battery is kept charged by taper charging through a series resistor.

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SEC-100BRM has 5 PSMs of 20 A each providing a total of 100 A

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SEC-80BRM has 4 PSMs of 20 A each providing a total of 80 A

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SEC-60BRM has 3 PSMs of 20 A each providing a total of 60 A

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SEC-40BRM has 2 PSMs of 20 A each providing a total of 40 A

COOLING AND WARNING FOR FAN FAILURE

The heat generated due to internal power dissipation is removed by forced cooling through two high power D.C. fans mounted at the back of the unit which suck air from the vents on the sides of the unit & blow outwards from the rear of the unit.

IT IS EXTREMELY IMPORTANT THAT THE DISCHARGE SIDE OF THE FANS AND THE SUCTION SIDES OF THE VENT SLOTS ARE NOT BLOCKED.

A warning circuit monitors the operational condition of the fans. In case of a fan failure, a buzzer will sound and the red LED indicating “FAN FAILURE” will light up. The unit should be switched off immediately and the defective fan should be replaced. NEVER LOAD THE UNIT WHEN THERE IS AN AUDIBLE ALARM AND THE FAN FAILURE LED IS ILLUMINATED.

The 2 fans are rated for 12 V nominal and are powered from the output voltage of the modules. A small Printed Circuit Board (PCB) located on the right corner towards the back of the unit is used to monitor the fans for abnormal operating conditions viz. open circuit or overload condition due to obstructed rotor.

FRONT PANEL CONTROLS AND INDICATORS

The following controls and indicators are provided on the front panel :

1A. POWER ON/OFF SWITCH. The rocker switch will illuminate when switched on. 1B. BREAKER. A 25A circuit breaker provides protection on the input side against overload

2. VOLTMETER / AMMETER. A combined voltmeter and ammeter are provided. The function

can be switched by the Volt / Amp switch (3)

3. METER CHANGE-OVER SWITCH. Switches the combined meter between ammeter and

voltmeter

4. L.E.D “ PSM STATUS (1 to5)”. During normal operation, the green LED of each Power

Supply Module (PSM) will light. In case a power supply module (PSM) fails, its corresponding

LED will go off. LED 1 is for the left most module (near the on/off switch)

5. L.E.D “FAN FAILURE ”: In case of fan failure, this red LED lights up and a buzzer is

sounded.

1B.

1A.

REAR PANEL CONNECTORS

The following output connectors have been provided (Not shown).

1. Load+ (Positive), Load- (Negative) LOAD CONNECTORS. For connecting to the D.C. Load

2. Battery+ (Positive), Battery- (Negative) BATTERY CONNECTORS For connecting external battery for un-interrupted D.C. power to the load.

REMOTE MONITORING AND SIGNALLING

A provision has been made for remote signaling and monitoring of the following operational conditions and parameters:

1. Operational status of the 5 Power Supply Modules (PSM)

2. Failure condition of the cooling fan(s)

3. Availability of AC input power

4. Output voltage measurement

5. Output current measurement ( Voltage across an internal shunt with Shunt ratio of 50 mV / 100 A or 0.5 mV per Amp)

Signaling of operational conditions as at serials 1, 2 and 3 above is opto coupled with open collector, NPN transistor outputs. The collector and emitter of each opto coupled transistor are accessible to the external user interface through the 25 pin D-Sub connector. Each open collector, opto coupled NPN transistor can provide a maximum of 50 mA with a collector to emitter voltage of up to 35 V. Outputs for voltage and current measurements at Serials 4 & 5 above are direct analogue voltages. The pin out of the 25 pin D-Sub connector providing the above signals for user interface is given below:

Item Pin

1 2 Black Collector AC input is available

16 White Emitter

2 12 Orange Collector Fan failure

19 Green Emitter

3 7 Gray Collector PSM 1 Normal

20 Violet Emitter

4 8 Violet Collector PSM 2 Normal

21 Blue Emitter

5 9 Blue Collector PSM 3 Normal

22 Green Emitter

6 10 Green Collector PSM 4 Normal

23 Yellow Emitter

7 11 Yellow Collector PSM 5 Normal

24 Orange Emitter

8 25 Red - Voltmeter +

13 Black - Voltmeter -

9 18 Gray - * Ammeter +

6 Blue - * Ammeter -

* This signal is the voltage across an internal shunt at 0.5 mV per Amp (Shunt Ratio is 50 mV / 100 A)

No.

Color Code of Wire

Output Pin of Opto-coupler

Operational Condition or Parameter (High)

PROTECTIONS

SHORT CIRCUIT PROTECTION: In the event of a short circuit, the PWM controller will be shut down and

the output will drop to near 0 V. The green LEDs will flash. The unit will reset automatically once the short circuit condition is removed

CURRENT LIMITING: The unit will enter this mode when the load tries to draw more than the limiting values of currents as shown in the specifications. Under this condition, there will be loss of voltage regulation and the output voltage will drop. The “PSM STATUS” LEDs will, however, remain illuminated, but dimmed. When the overload reaches approximately 140A for SEC-100BRM or 112A for SEC-80BRM or 84A for SEC-60BRM or 56A for SEC-40BRM (the output voltage will be approximately 2.7V), the unit will shut down (will enter hiccup mode). The PSM status LEDs will start flashing and PSM status signal for remote indication will oscillate between High and Low. The unit will reset automatically as soon as the overload condition is re-

moved . INPUT SURGE PROTECTION : The unit is protected against input voltage surges. In case of input spike/

surge, the A.C. side breaker will trip. The 4A fuse on the module will also blow.

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