AUTOMATIC BATTERY CHARGER

Transcription

1 AUTOMATIC BATTERY CHARGER SAMLEX AMERICA. MODELS SEC A SEC A SEC A OWNER'S MANUAL Please read this maual before operatig your charger.

2 Cotets SAFETY, INPUT VOLTAGE SELECTION... 1 INTENDED USE, FEATURES... 2 INSTALLATION & CONNECTION... 3 OPERATION... 4,5 TROUBLESHOOTING... 6,7 SPECIFICATIONS... 8 WARRANTY INFORMATION... 9

3 Samlex America Ic. Automatic Battery Charger Geeral Safety ad Istallatio Istructios ABOUT THE BATTERY CHARGER : The Samlex charger must oly be used for the purposes specified. Whe workig o the charger, always discoect it from the mai AC power source. Do ot operate the charger if the housig or cables are damaged. The charger must be positioed ad secured i such a way that it caot fall over or fall dow. The metal housig is coected to the groud coductor of the 120V or 230V plug. The coector cable from the charger must be plugged ito grouded outlets oly. The charger must be kept i a safe place, out of the reach of childre. The charger must ot be operated i a damp or wet eviromet. Esure good vetilatio. Servicig ad repair must oly be performed by a qualified techicia who is familiar with the risks ivolved. Do ot supply curret to exteral circuit while chargig a battery. (See cautio o page 4) WRONG INSTALLATION OF ELECTRICAL UNITS ON BOATS CAN LEAD TO CORROSION OF THE BOAT. THEREFORE, PLEASE LET A BOAT ELECTRICIAN CARRY OUT THE INSTALLATION OF THE CHARGER. SELECTING INPUT VOLTAGE CAUTION These uits are pre-set to operate from iput voltage of 115 VAC, 60HZ. The power cord has a molded 3-pi North America plug. These uits ca also operate from a iput voltage of 230 VAC, 50 HZ. This requires chage of jumper positio ad the AC side fuse iside the uit. The procedure for makig this chage is as follows: 1. Remove the 4 screws o the ammeter side of the top cover 2. Getly slide the top cover out by about 2 to 3 iches. (CAUTION! The top cover will be restraied from fully slidig out by the wires coectig the ammeter, LED ad fa) 3. Locate the jumper wire coected to the male vertical pi marked 115 V ad the male vertical pi marked 230 V. Remove the female quick coect termial from the 115V positio by getly pullig it upward. Now coect it to the male vertical pi marked 230 V. 4. Replace the fuse with ew fuse (see iteral fuse ratigs o page 7 ) 5. Slide the top cover back ad fix with the 4 screws 6. Use adapter to covert the plug to suit the 230 VAC receptacle or chage the plug. (CAUTION! The ew plug should have 3 poles - live, eutral ad groud. Color code for the 3 wires of the power cord is: Live - Black ; Neutral - White ; Chassis groud - Gree) Page 1

4 ABOUT THE CABLES: Cable routig ad istallatio iformatio If cables have to be iserted through metal walls or other sharp-edged material, use a cable duct or cable bushig Do ot lay cables loose or with sharp beds o electrically coductive materials (metal). Secure the cables properly. Lay cables i such a way that o oe ca trip over them. Lay cables i such a way that they are ot exposed to the risk of damage. Do ot lay 120V or 230V mai cable ad 12V/24V DC cable together i the same duct. The specified miimum cross-sectio must be complied with. Do ot pull cables. INTENDED USE The use of a high efficiecy Pulse Width Modulatio Switchig Cotroller makes the istallatio-friedly Samlex charger very small, light ad powerful. Together with the mechaical stregth, over temp. ad short circuit protectios, esure high operatig safety. Because of these features, the charger is ideal for mobile uses i motor homes, o board motor or sailig yachts or i ambulaces ad emergecy rescue vehicles. SAMLEX CHARGER FEATURES Small, light ad robust i desig ad maufacture. Fully automatic Coect ad Forget operatio Output curret limitig ad short circuit shutdow. Easy istallatio by brackets o the housig. 3 stage characteristic for rapid ad complete battery chargig. 3 bak chargig (3 positive + termials) Moitorig through ON status LED ad Ammeter Coolig by temperature cotrolled fa (SEC-1230A & SEC-2415A) Page 2

5 INSTALLATION WARNING! BEFORE PLUGGING THE UNIT TO THE AC OUTLET, PLEASE CHECK THAT YOUR LOCAL SUPPLY VOLTAGE IS 115 VAC. IF YOUR LOCAL SUPPLY VOLTAGE IS 230 VAC, CHANGE THE INTERNAL VOLTAGE SELECTION TO 230 VAC ( SEE UNDER SELECTING INPUT VOLTAGE ON PAGE 1 ) Samlex chargers are desiged for easy istallatio. Whe istallig your charger, make sure to locate the charger i a place with easy access to (1) AC 115V or 230V 60Hz or 50Hz source, (2) the batteries, (3) free air circulatio. Also make sure that the charger is istalled i a dry area, well sheltered from weather ad water spray. Mout the charger i a vertical positio, with a miimum of 4 iches space for vetilatio o the top, bottom ad sides. THE CHARGER SHOULD BE MOUNTED IN A VERTICAL POSITION ONLY. Never store aythig o top of the charger. If mouted i a compartmet, vetilate the compartmet with louvers or cutouts, ad keep this space free of other items. Cables It is recommeded that two colors be used for the wires from the charger to the batteries: Red ( +) ad Black ( - ) Proper wire size is as follows: Legth up to 15 ft : #12 AWG Legth up to 25 ft: #10 AWG CONNECTION 1. Coect the ( + ) positive termial of the battery to the ( + ) positive termial of the charger. Coect the ( - ) egative termial of the battery to the ( - ) egative termial of the charger. CAUTION! REVERSING POLARITY WILL DAMAGE THE CHARGER. DAMAGE CAUSED BY REVERSING POLARITY IS NOT COVERED BY YOUR WARRANTY. 2. Up to three batteries ca be coected to the 3 ( + ) positive termials. The ( - ) egative termial is commo. Note : The total specified maximum chargig curret is shared by the 3 ( + ) positive termials. 3. Verify that the AC lie iput is set for proper lie voltage (see page 1). 4. Check wirig to verify proper coectios before applyig power. 5. Plug i the AC iput lie to tur o the AC power. The red LED lights idicatig availability of DC power ad the ammeter idicates the coditio of the battery uder chargig. Page 3

6 OPERATION IMPORTANT NOTE - VOLTAGE READINGS ON NO LOAD THE OUTPUT HAS ONE COMMON NEGATIVE TERMINAL AND 3 POSITIVE TERMINALS TO ENABLE CONNECTION OF 3 BANKS OF BATTERIES. EACH POSITIVE TERMINAL HAS GOT ITS OWN ISOLATING DIODE.THE OUTPUT VOLTAGE AT THE POSITIVE TERMINAL WHICH IS NOT LOADED (I.E. A BATTERY OR ANY OTHER LOAD IS NOT CONNECTED TO IT), WILL MEASURE 0.8 V TO 1.1 VOLTS HIGHER THAT THE SPECIFIED NOMINAL FLOAT (MAINTENANCE) VOLTAGE AND NOMINAL BOOST (OVERCHARGE) VOLTAGE. CHARGING STAGES STAGE 1 - BULK CHARGE MODE Whe the battery is low, it will attempt to draw a large chargig curret. The charger seses the curret draw ad limits this to the maximum permissible value. (15A for SEC-1215A ad SEC-2415A ad 30A for SEC-1230A). Bulk chargig takes place at this costat curret. The battery voltage determies the charger s output voltage. As the battery capacity is restored, its voltage rises ad its curret draw gradually reduces. Whe the curret draw by the battery goes below the maximum permissible value, the charger will automatically make the trasitio to STAGE 2. STAGE 2 - OVER CHARGE or BOOST CHARGE MODE Cotrolled over charge ( or boost charge ) follows bulk chargig to restore full capacity i a miimum amout of time. I this mode, the charger outputs a costat voltage of 14.3V (14.9 V by chagig the settig iside the charger )for 12V system or 28.6V (29.8V by chagig the switch settig iside the charger )for 24 V system. As the battery approaches full capacity, its curret draw further reduces. Whe this curret is betwee 1.5A ad 3A, the charger the automatically makes the trasitio to STAGE 3. STAGE 3 - FLOAT or MAINTENANCE CHARGE MODE The charger goes ito this mode if it seses a curret draw of less tha 1.5A to 3A. This coditio will result whe the battery is fully charged ad eeds very low curret to compesate for self-discharge. The charger outputs a costat voltage of 13.8V for 12 V system ad 27.6 V for 24 V system. This helps i maitaiig the capacity of the battery agaist self-discharge. CAUTION These chargers have bee pre-set to operate i 3 stage algorithm. Please esure that the battery is ot supplyig ay exteral load whe it is beig charged. If the exteral load draws more tha 1.5 to 3A, the charger will ot eter Stage 3 - float or maiteace charge mode (Output 13.8V or 27.6V) ad will remai i Stage 2 - boost mode (Output 14.3V / 14.9V or 28.6V / 29.8V). The situatio will lead to overchargig of the battery ad boilig. I order to charge a battery as well as supply a exteral load, the charger has to be iterally adjusted to bypass Stage 2. PLEASE CALL SAMLEX TECHNICAL SUPPORT AT (604) FOR ASSISTANCE IN THIS REGARD Page 4

7 OPERATION 1 If your battery is ot fully charged, the chargig meter will idicate curret draw. As the battery approaches beig fully charged, the chargig curret will decrease. 2 Whe the meter reads zero, the battery is fully charged. These chargers are fully automatic ad require o maiteace i ormal operatio. 3 A overload coditio caused by a accidetal, exteral short circuit or defective, iterally shorted battery, will shut dow the charger. The ON status LED will tur off. O removal of the short circuit coditio, the charger will automatically resume chargig. 4 Short-term overload caused by chargig a completely discharged good battery will ot damage the charger. 5 A boat egie or geerator ca be started without upluggig or discoectig the battery charger. 6 Nickel-cadmium batteries ad ochargeable batteries must ot be charged with the charger. The casig of these batteries ca burst. CHANGING BOOST VOLTAGE The boost voltage is pre-set at 14.3 V for SEC-1215A ad SEC-1230A, ad 28.6 V for SEC-2415A. This boost voltage ca be chaged to 14.9 V for SEC-1215A ad SEC-1230A, ad 29.8V for SEC-2415A. The procedure for this is as follows: 1 Remove the 4 screws o the ammeter side of the top cover 2 Getly slide the top cover out by about 2 to 3 iches. (CAUTION! The top cover will be restraied from fully slidig out by the wires coectig the ammeter, LED ad fa) 3 Locate the slider switch marked SW 1 located ear the coectio for the output termials. Slide the switch over to the other positio 4 Replace the top cover. COOLING AND THERMAL OVERLOAD SHUTDOWN CAUTION! KEEP THE UNITS IN A WELL VENTILATED COOL OPEN AREA. DO NOT BLOCK THE VENT HOLES ON THE SIDES OR THE SUCTION OPENINGS OF THE COOLING FAN. SEC-1215A is cooled by covectio. It does ot have thermal overload shutdow. SEC-1230A ad SEC-2415A are cooled by covectio as well as temperature cotrolled fa. Two temperature sesors mouted o the power trasformer cotrol the switchig of the fa ad over temperature shutdow. The fa will be switched o whe the power trasformer reaches 70 C. HENCE, AT LOWER LOADS, THE FAN MAY NOT CUT IN AND WILL BE OFF. THIS IS NORMAL. If the fa fails or if the coolig is ot adequate due to poor vetilatio, the secod temperature sesor will shut dow the uit whe the power trasformer reaches 100 C. The uit will automatically reset oce the uit cools dow. Page 5

8 TROUBLESHOOTING SYMPTOMS WHEN THE CHARGER IS POWERED AND CONNECTED TO THE BATTERY THE RED LED IS OFF The DC side fuse may have blow due to wrog polarity of battery coectio. Esure positive of the battery is coected to the positive of the charger ad the egative of the battery is coected to the egative of the charger. Check the DC side fuses iside the charger ad replace, if blow The battery may be shorted. I this coditio, the uit is shut dow by the short circuit protectio circuit. Remove the battery coectio. If the LED ow comes o, the battery is shorted. If the LED still does ot come o, check there is AC power i the receptacle. If there is power, check the AC side fuse iside the uit. If the fuse is ot blow, call techical support. THE RED LED IS ON BUT THE AMMETER SHOWS NO READING The battery is fully charged. If the battery is ot fully charged, the coectio to the battery may be loose or ope. Check tightess ad cotiuity of the battery coectio. THE BATTERY IS GETTING OVER CHARGED OR BOILS The uit is also feedig exteral circuit (s) i parallel with the battery. The curret draw by the exteral circuit(s) is prevetig the uit from revertig to the float coditio (see uder cautio o page 4). Discoect the exteral load whe chargig battery. SYMPTOMS WHEN THE CHARGER IS POWERED AND DISCONNECTED FROM THE BATTERY THE RED LED IS OFF Check there is AC power i the receptacle. If there is power, check the AC side fuse iside the uit. If the fuse is ot blow, check the DC side fuse. If the dc side fuse is ot blow, the output may be shorted. I this coditio, the charger is shut dow by the short circuit protectio circuit. Check that the output termials are ot shorted. If the termials are ot shorted, call techical support AC SIDE FUSE BLOWS AS SOON AS POWER IS TURNED ON The AC iput is selected for 115 VAC but the uit is plugged ito 230 VAC. Always check that the charger is set for the correct AC mais voltage Page 6

9 If the AC iput voltage is correct, the charger is defective. Call techical support DC SIDE FUSE BLOWS AS SOON AS THE BATTERY IS CONNECTED Wrog polarity. Esure positive of the battery is coected to the positive of the charger ad the egative of the battery is coected to the egative of the charger SYMPTOMS WHEN THE CHARGER IS POWERED AND IS BEING USED AS A DC POWER SUPPLY THE VOLTAGE DROPS WHEN LOAD IS SWITCHED ON The load is tryig to draw curret more tha the curret limit value of the charger. Oce the load curret reaches the curret limit value, the curret limit circuit is activated ad the output voltage drops. Some loads like motors, compressors, icadescet lamps, haloge lamps, heatig elemets, relays, coils, capacitors etc. draw very large irush/startig currets, which may reach up to 10 times their ormal operatig currets. Esure that the startig / irush curret or the maximum operatig curret of the load is lower tha the curret limit value of the charger INTERNAL FUSE RATINGS Both the AC side ad DC side have fuses that are located iside the charger. Discoect the AC power whe checkig or chagig the fuses. Ope the charger as follows: 1. Remove the 4 screws o the ammeter side of the top cover 2. Getly slide the top cover out by about 2 to 3 iches. (CAUTION! The top cover will be restraied from fully slidig out by the wires coectig the ammeter, led ad fa 3. The fuses will ow be accessible The fuse ratigs are as uder: SEC-1215A SEC-1230A SEC-2415A 115 V : AC Iput 4A/125V 8A/250V 8A/250V DC Output 20A/32V 20A/32V (2) 10A/32V (2) 230V: AC Output 2A/250V 4A/250V 4A/250V DC Output 20A/32V 20A/32V (2) 10A/32V (2) Page 7

10 SPECIFICATIONS SEC-1215A SEC-1230A SEC-2415A Iput Voltage (Pre-set) Volts, 60 Hz Volts, 60Hz Volts, 60 Hz (Iteral Jumper Chage) Volts, 50 Hz Volts, 50 Hz Volts, 50 Hz Iput Frequecy Hz Hz Hz Output Voltage, Boost 14.3V( Pre-set) *14.9V 14.3V( Pre-set) *14.9V 28.6V( Pre-set) *29.8V Output Voltage, Float 13.8V 13.8V 27.6V Output Amps 15A 30A 15A Operatig Temp. Rage 0-55 C 0-55 C 0-55 C Weight 1.9kg / 4.2 lbs. 2.4kg / 5.28 lbs. 2.4kg / 5.28 lbs. Housig Dimesios L X W X H Iches Cms 8 x 33 x 8I 20.3 x 8.25 x x 33 x 8I 25.4 x 8.25 x x 33 x 8I 25.4 x 8.25 x 21.3 Protectios Short Circuit Overload Short Circuit Overload Over temperature Short Circuit Overload Over temperature Output Baks * Note : Switch positio, located o the circuit board, must be chaged to icreas eboost voltage to 14.9V (SEC- 1215A & SEC-1230A) or 29.8V (SEC-2415A). See chagig Boost Voltage o page 5. Specificatios are subject to chage without otice. Page 8

11 1 YEAR Limited Warraty SEC-1215A/SEC-1230A/SEC-2415A maufactured by Samlex America, Ic. ( the Warrator ) is warrated to be free from defects i workmaship ad materials uder ormal use ad service. This warraty is i effect for 1 year from the date of purchase by the user ( the Purchaser ) For a warraty claim, the purchaser should do the followig : 1. Prepare a writte statemet of the ature of the defect to the best of the Purchaser s kowledge, ad iclude the date of purchase, the place of purchase, ad the Purchaser s ame, address ad telephoe umber. 2. Call Samlex America, Ic or 1 (604) ad request a Returig Merchadise Authorizatio Number ( RMA ). 3. Retur the defective part or uit alog with the statemet at the Purchaser s expese to the Warrator ; Samlex America Ic., # Fawcett Road, Coquitlam, B.C. V3K 6V2 Caada. The RMA umber must be marked clearly o the outside of the packagig. If upo the Warrator s examiatio, the defect proves to be the result of defective material or workmaship, the equipmet will be repaired or replaced at the Warrator s optio without charge, ad retured to the Purchaser at the Warrator s expese. No refud of the purchase price will be grated to the Purchaser, uless the Warrator is uable to remedy the defect after havig a reasoable umber of opportuities to do so. Warraty service shall be performed oly by the Warrator. Ay attempt to remedy the defect by ayoe other tha the Warrator shall reder this warraty void. There shall be o warraty for defects or damages caused by faulty istallatio or hook-up, abuse or misuse of the equipmet icludig exposure to excessive heat, salt or fresh water spray, or water immersio. No other express warraty is hereby give ad there are o warraties which exted beyod those described herei. This warraty is expressly i lieu of ay other expressed or implied warraties, icludig ay implied warraty of merchatability, fitess for the ordiary purposes for which such goods are used, or fitess for a particular purpose, or ay other obligatios o the part of the Warrator or its employees ad represetatives. There shall be o resposibility or liability whatsoever o the part of the Warrator or its employees ad represetatives for ijury to ay persos, or damage to perso or persos, or damage to property, or loss of icome or profit, or ay other cosequetial or resultig damage which may be claimed to have bee icurred through the use or sale of the equipmet, icludig ay possible failure of malfuctio of the equipmet, or part thereof. The Warrator assumes o liability for icidetal or cosequetial damages of ay kid. Page 9

12 SAMLEX AMERICA Fawcett Road Coquitlam B.C., Caada V3K 6V2 website: SEC1215A/1230A/2415A Ver.B (050801)