SETEC MODEL
BCE4 & BCE5
USER’S MANUAL
Document No 010812
Issue D Page 1 of 13
Manufactured by:
SETEC Pty Ltd
19 Henderson Road
Knoxfield 3180
AUSTRALIA
Phone: +61 3 9763 0962
Fax: +61 3 9763 8789
Email: sales@setec.com.au
WARNING:
This product Contains Hazardous voltages which can cause
death. It should only be serviced by properly qualified
personnel.
The product contains no user serviceable parts.
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CONTENTS
INTRODUCTION......................................................................................................... 4
OPERATION............................................................................................................... 5
Safety .................................................................................................................. 5
Operating Modes................................................................................................. 5
Protection............................................................................................................. 5
Battery LVD Operation......................................................................................... 6
Indicators............................................................................................................. 6
Alarm ...................................................................................................................6
Output Voltage Adjustment.................................................................................. 6
SPECIFICATION......................................................................................................... 8
MECHANICAL............................................................................................................. 9
MOUNTING............................................................................................................... 10
INSTALLATION......................................................................................................... 11
Personnel .......................................................................................................... 11
Mounting Options............................................................................................... 11
Connectors ........................................................................................................ 11
Hooking Up........................................................................................................ 11
Cabling .............................................................................................................. 12
Battery Fuse ...................................................................................................... 12
Cooling .............................................................................................................. 13
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INTRODUCTION
The SETEC models BCE4 and BCE5 (battery charger/eliminator) provide a power
output of 140 watt at 13.6 and 27.2V respectively. The nominal input mains may be
200V to 240V and 50Hz or 60Hz (a 100 to 120V version is available, consult the
factory for details).
The BCE4 and BCE5 have been designed specifically for telecommunications
applications demanding high reliability, low noise, fully automatic battery backup,
battery protection and full protection of the output. Many other applications will be
able to take advantage of these features. Features include
• Light compact design
• High Efficiency
• Battery over discharge protection with automatic reset
• High reliability with conservative thermal design allowing continuous full load
operation with convection cooling
• Alarm for low mains and reverse battery connection
• User accessible battery fuse
• User accessible output voltage adjustment
• Low noise output, ideal for telecommunications applications
• 3 modes of operation
• Convenient output connector
• Flexible mounting options
• Full protection for the power supply, load and battery
• Local technical support
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OPERATION
Safety
Correct installation is the most critical factor in ensuring the safe use of
the power supply. If every consideration in the Installation section of this
manual has been satisfied the power supply will be safe to operate.
Operating Modes
The BCE4 and BCE5 have three main operating modes:
• As a battery eliminator it may be used to power equipment requiring
12V –14V at 10Amps. (24 –28V at 5Amps for BCE5). It is fully
protected against overload and short circuit as well as incorporating
over voltage protection.
• As a lead acid battery charger it will provide safe and convenient
method to restore discharged batteries. Fully charged batteries can
be left connected to the unit indefinitely with no adverse effects on
their lifetime.
• The full features of the unit are realised when both a battery and a
load are connected so that it operates as a power supply with power
fail protection. Under normal conditions an internal switch connects
the battery in parallel with the load. The average load must be less
than the capability of the power supply to ensure there is a remainder
available to float charge the battery.
When a mains failure occurs, the power supply no longer provides
power. The battery now supports the load without interruption of the
load. Restoration of the mains restarts the power supply which will
resume support of the load and charging of the battery.
During extended mains failures the unit disconnects the battery
before it becomes excessively discharged. The battery is
automatically reconnected when the mains recovers. This feature
contributes to long battery lifetime and allows unattended operation of
a system.
Protection
The power supply incorporates the following protection features
• Reverse polarity connection of the battery will not cause damage to
the power supply or the battery and the output load will remain
unaffected.
• Battery fusing is provided in series with battery connection to protect
the load and power supply when it is powered from the battery.
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• Accurate current limit protection is provided for both load and battery.
Automatic recovery from short circuit is provided with no current
tailing in short circuit operation.
• Over voltage protection provides shutdown of power supply.
• Inrush Surge limiting at turn on.
Battery LVD Operation
A low voltage disconnect (LVD) is provided to prevent deep discharge of
the battery.
When the mains has failed and the battery is supporting the load the
battery must be disconnected if its voltage falls below 10.2V ±0.2V (20.5V
±0.6V for BCE5) for longer than approximately 800mS.
The battery will reconnect in such a case when either;
1. The mains has recovered and the battery voltage is > 9.5V or;
2. The battery voltage has recovered to greater than 11.9V ±0.3V
(23.5V ±0.7V for BCE5) for longer than approximately 2 seconds.
The BATTERY output has protection incorporated against a reversed
battery connection. A reversed battery is left disconnected so that the
LOAD output can still run the load from mains power.
The quiescent current drain on the battery when the main has failed is
less than 30mA.
Indicators
A green LED (located next to the output connector) is illuminated during
normal operation. An alarm condition extinguishes the LED.
Alarm
A green LED and a pair of normally closed, floating relay are provided to
indicate alarm conditions. The LED is illuminated and the alarm relay
contacts are open during normal operation. An alarm condition
extinguishes the LED and closes the relay contacts. Alarm conditions are
defined as any one or more of the following events:
The mains fails, or drops to below nominal input.
The battery has been connected backwards.
Output Voltage Adjustment
The output voltage is adjustable through the side of the power supply.
Use a flat blade pot adjuster to adjust the output voltage. Clockwise
rotation increases the output voltage.
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When adjusting the output voltage, measure the voltage at the output
connector with the battery disconnected. Failure to disconnect the battery
can result in incorrect output voltage setting, and over charging of the
battery may result.
The output voltage is factory set to 13.65V (27.20V for BCE5)
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SPECIFICATION
The following table lists the specifications of the BCE4 and BCE5
Specification
Input Voltage:
200-240V nominal, ±10%, 50/60Hz.
A 5 minute, +15% surge will not damage the power supply.
Input Surge:
<40A
Holdup Time:
>20mS, over the nominal input range
BCE4 BCE5
Output Voltage:
12.0 –14.0V Adjustable 24.0 – 28.0V Adjustable
Output Voltage factory set:
13.65V 27.20V
Output Ripple Voltage:
< 20mVp-p < 20mVp-p
Output Current:
10.0A 5.0A
Over Voltage Protection:
< 16.0V < 32.0V
Battery Disconnect
10.2 ± 0.2V 23.5 ± 0.7V
Battery Reconnect
&
11.9 ± 0.3V 20.5 ± 0.6V
Battery Hysteresis
1.7V typ 3.0V typ
Battery Fuse
15A, 32Vdc 10A, 32Vdc
Load Regulation 1:
± 2% from set point taking into account all of line and load
regulation and temperature coefficient when load powered by
power supply
Load Regulation 2:
+0 –2% of battery terminal voltage when load powered by
battery.
Alarm Relay Contact
Rating
Normally closed contacts
60V @ 0.2A
Operating Environment:
0 – 50’C Ambient. Convection cooled
Efficiency:
90% typ
Mechanical
See figures 1 - 6
Weight
< 1Kg
Compliance:
AS/NZS 60950-1 : 2003
AS/NZS CISPR22 Class A
ACA EMC Compliance, C-Tick Mark
&
Battery is automatically connected if mains is present and the battery voltage is > 9.5V.
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MECHANICAL
111.0 224.0
59.0
Figure 1 – Overall Dimensions
63.0
186.5
15.3
81.6
47.8
13.0
5.5
10.0
Figure 2 – Mounting Points
Turn clockwise
to increase
output voltage
Figure 3 – Voltage Adjustment
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MOUNTING
Maximum protrusion
of M3 screw into
chassis is 4mm
M3 Screw
Front Panel
Figure 3 – Front Panel Mounting
Rubber Feet
Flat Washer
M3 x 8mm Screw
Figure 5 – Bench Mounting
M3 Screw
Maximum protrusion of M3
screw into chassis is 4mm
Mounting Panel
Figure 6 – Panel Mounting
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INSTALLATION
Personnel
Installation should only be conducted and/or closely supervised by
appropriately qualified personnel.
Mounting Options
The unit is supplied with 4 rubber feet for bench use. However, a number
of mounting options have been provided to suit various installations.
Mounting options have been provided at the front and the underneath of
unit in the form of M3 x 0.5mm threads. The unit can be mounted
horizontal or vertical to suit all types of installations. See figures 4 – 6.
The maximum thread length for these screws is 4mm from the outside
edge of the power supply. Hazardous Voltages exist within the power
supply so it is important that the screw lengths are adhered to.
Connectors
Input Mains: IEC320
DC Output: 6 Way female plugable type
Pinout for the DC output connector is as follows;
Pin Function
1 0V
2 0V
3 Load
4 Battery
5 Alarm 1
6 Alarm 2
Mating Connectors: Phoenix: MSTB 2.5/6-ST
Weco 120-A-111/06
Camden CTB9200/6A
Hooking Up
The requirements for wiring a BCE4/BCE5 into a system are as follows:
LOAD, 0V
These 2 connections are the DC output of the power supply. These
connections are to supply the load.
• These connections cannot be paralleled with output of duplicate
power supply for increased current output.
• The load connection must not be directly connected to the battery or
paralleled with the BATTERY connection. This will disable the battery
low voltage disconnect circuit and defeat the internal battery fuse.
Issue D Page 11 of 13
• Excessively long cable connections are not good practice. Try to keep
these lines to a minimum to reduce system voltage drop.
BATTERY, 0V
These 2 connections are to be connected to the battery.
• Ensure that the battery is connected with the right polarity. Although
reverse polarity will not harm the battery, power supply or the load, no
backup of the load will occur during a power outage.
• Consult battery manufactures data before use with the power supply.
• Excessively long cable connections are not good practice. Try to keep
these lines to a minimum to reduce system voltage drop.
RELAY
The 2 relay connections are the floating alarm relay contacts.
• Connect these pins to any circuit, which is required to be activated by
an alarm condition. The 2 pins become shorted when an alarm
condition occurs.
• These pins must not be connected to mains circuits or any other
hazardous voltage circuits.
Cabling
AC Cabling: A cable size of 0.75mm2 (18AWG) is recommended.
DC Cabling: A minimum cable size of 0.75mm
2
(18AWG) is
recommended for BCE5.
A minimum cable size of 1.5mm
2
(16AWG) is
recommended for BCE4
Note, maximum size of cable to output connector is 2.5 mm
2
or 12AWG
DC load cables must be sized to carry the maximum full load current and
not exceed the system volt-drop requirements.
Battery Fuse
Only replace battery fuse with the following type,
BCE4 BCE5
Battery Fuse: Bussman ATC-15 Bussman ATC-10
LittelFuse 257 015 LittelFuse 257 010
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Cooling
The BCE5 power supply has been design for convection cooling. It is,
therefore, very important that its natural airflow is unimpeded.
For maximum output power at maximum ambient temperature it is
recommended that the following spaces above and below the power
supply are provided.
Horizontal (bench) mounting Vertical mounting
60mm min 60mm min
20mm min
Note: The maximum ambient operating temperature of the power
supply is defined as the temperature of the air entering the bottom of the
power supply. This may not be the same as the room temperature if the
power supply is mounted above a heat source, or in a confined space.
If the objects above and below the power supply do not restrict the
airflow, (i.e. perforated metal) then the distances shown above may be
reduced. For more information contact the manufacturer.
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