manual

ARABIAN POWER ELECTRONICS COMPANY (APEC)

User Manual Battery Charger

SM SERIES

Dear Customer,

W e thank you for selecting our products and are pleased to count you amongst our very valuedcustomers.

We trust that the use of the SM Series Battery Charger system, developed and manufactured to thehighest standards of quality, will give you complete satisfaction.

Please read carefully the User Manual, which contains all the necessary information and describes allyou need to know about the use of the SM Series Battery Charger.

Thank you for choosing APEC.

START UP AND COMMISSIONING

APEC Services field engineer must perform start-up and commissioning of theBattery Charger systems. Please contact APEC Services at least one months priorto schedule start-up and commissioning at 00966 38901261 or by e-mail [email protected]

Manufacturer Distributor your service contact

Arabian Power Electronics CompanyP.O. Box, 3411Al-Khobar 31952 - KSA.Tel : 00966 38901261Fax: 00966 38650066

Warranty

The instruments are warranted against defects in material and workmanship for a

period of one year from the date of shipment. This warranty is subject to this

instruments use with its electrical, electronics environmental & mechanical

specification as explained in this user manual. Manufacturer agrees to repair or

replace any assembly or component found to be defective, under normal use

during this period.

Manufacturer obligation under this warranty is limited solely to repairing any such

instrument which in Manufacturer's sole opinion proves to be defective within the

scope of the warranty when returned to the factory or to an authorized service

centre. Transportation to the factory or service centre is to be prepaid by the

purchaser. Shipment should not be made without prior authorization by

Manufacturer.The Warranty is covered only for labour and parts.

This warranty does not apply to any products repaired or altered by persons not

authorized by Manufacturer, or not in accordance with instructions furnished by

Manufacturer. If the instrument is defective as a result of misuse, improper

repair, or abnormal conditions or operations, repairs will be billed at cost.

Manufacturer assumes no responsibility for its product being used in a

hazardous or dangerous manner either alone or in conjunction with other

equipment. High voltage used in some instruments may be dangerous if misused.

Special disclaimers apply to these instruments. Manufacturer assumes no liability

for secondary charges or consequential damages and in any event,

Manufacturer's liability for breach of warranty under any contract or otherwise,

shall not exceed the purchase price of the specific instrument shipped and

against which a claim is made.

Any recommendations made by Manufacturer for use of its products are based

upon tests believed to be reliable, but Manufacturer makes no warranty of the

results to be obtained. This warranty is in lieu of all other warranties, expressed

or implied, and no representative or person is authorized to represent or assume

for Manufacturer any liability in connection with the sale of our products other

than set forth herein.

SAFETY INSTRUCTIONWARNING

HAZARDOUS VOLTAGES IN EXCESS OF 230VRMS, 400VPEAK MAY BE PRESENT WHEN COVERS ARE REMOVED.QUALIFIED PERSONNEL MUST USE EXTREME CAUTION

WHEN SERVICING THIS EQUIPMENT. CIRCUIT BOARDS,TEST POINTS AND OUTPUT VOLTAGES MAY ALSO BE

FLOATING ABOVE (BELOW) CHASSIS GROUND.

QUALIFIED PERSONNEL who are aware of properly dealing with attendanthazards must perform installation and servicing. This includes such simpletasks as fuse verification and channel reconfiguration.

Ensure that the AC power line ground is properly connected to the ModelSM2000 input connector. Similarly, other power ground lines includingthose to application and maintenance equipment MUST be properlygrounded for both personnel and equipment safety.

Always ensure that AC input power is de-energized prior to connecting ordisconnecting the power cable. Similarly, the Model SM2000 Line inputswitch must be switched OFF prior to connecting or disconnecting LOADS.

In normal operation, the operator does not have access to hazardousvoltages within the chassis. However, depending on the applicationconfiguration, HIGH VOLTAGES HAZARDOUS TO HUMAN SAFETY may benormally available on the output terminals if it is connected to a load. TheUser must ensure that the Source Output lines be properly labeled as tothe SAFETY HAZARDS and any that inadvertent contact with hazardousvoltages is eliminated.

Guard against risks of electrical shock during open cover checks by NOTTOUCHING any portion of the electrical circuits. Even when power is OFF,capacitors are well known to retain an electrical charge. Please allowsufficient time for discharge of storage elements before opening the cover.Use SAFETY GLASSES during open cover checks to avoid personal injuryby any sudden component failure.

Always replace the fuse with the appropriate rating only.

UM SM XXXXDEC 2013

USER'S MANUALBATTERY CHARGER

MODEL – SM XXXX

CONTENTS

CHAPTER 1 : GENERAL INFORMATION

CHAPTER 2 : INSTALLATION

CHAPTER 3 : OPERATING INSTRUCTIONS

CHAPTER 4 : MAINTENANCE

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C H A P T E R 1

GeneralInformation

INTRODUCTION

SM SERIES battery charger is the version of standard SM -1000modules. These are combination of SM 1000 modules connected in parallel.This gives the user the option of 1 TO 6 KW power in single module with allfunctions with the single operating mode.

Standard SM1000, Switch mode Power supply/ Battery Charger is availableas a compact 19" Rack type module that can be operated in parallel with seriesdiode at the output for redundant operation.

These modules are easy to install and operate. Various options formounting are available in addition to standard Euro Rack plug in system.Those will be supplied against specific request.

Features

19" Rack construction Wide input range Equal current sharing parallel operation possible Abnormal condition alarm Output Boost facility 7 Segment display for voltage and current measurement Single turn potentiometer for output voltage Built in protections for output over voltage and over temperature

with indications on individual modules.

SPECIFICATIONS

OUTPUT

SM1000 SM2000 SM3000 SM4000 SM5000 SM6000 VOLTAGERANGE

24V/40A 24V/80A 24V/120A 24V/160A 24V/200A 24V/240A 23-28 VDC36V/30A 36V/60A 36V/60A 36V/120A 36V/150A 36V/180A 34-42 VDC48V/20A 48V/40A 48V/60A 48V/80A 48V/100A 48V/120A 46-56 VDC60V/16A 60V/32A 60V/48A 60V/64A 60V/80A 60V/96A 58-70 VDC110V/9A 110V/18A 110V/27A 110V/36A 110V/45A 110V/54A 100-130

VDC125V/7.9A 125V/15.8A 125V/24.7A 125V/31.6A 125V/39.5A 125V/47.4A 124-135

VDC220V/4.5A 220V/9A 220V/13.5A 220V/18A 220V/22.5A 220V/27A 200-260

VDC1000W 2000W 3000W 4000W 5000W 6000W

Regulation Better than +/- 2%, + one diode drop.

Ripple <1% p-p of nominal output Voltage.

Recovery time 1ms typical.

Parallel Operation One or more units can be used in parallelfor higher power capacity.

Alarms Output falls below 85% of nominalvoltage alarm by potential-freechangeover contact- loadable with220V/1A/40W

Boost Charging 5% Higher than nominal output typical.(Resistor in sense line)

INPUT

Voltage a) 185-264 VAC, 45 - 65 Hz.b) 320-457 VAC,45-65 Hz

NOTE: 3 phase distribution will be provided onlywith the SM3000, SM4000, SM5000 &SM6000 .

Current Each SM1000 model take 9 Amps Typicalat220 VAC.

Inrush current Limited by NTC 7 ohm in individualmodules

Power factor 0.75 Typical Capacitive.

Hold up time 20ms typical / 230V

Crest factor 2.5

RFI EN55022-“A”

PROTECTIONS

Over Voltage & Over Temp Electronic Turn OFF for Output over-voltage and over-temperature; resetthrough panel push button switch onindividual modules.

IndicationsMain Panel LED Green = Float.

LED Red = Boost7 Segment DPM for output voltage &current measurement.

SM1000 Module LED Green = ONLED Red = Output over voltageLED Red = Output over temperature

ControlsMain Panel Input ON / OFF circuit breaker.

Output Voltage set potentiometer.Float / Boost switch.

SM1000 Module Potentiometer = Output Voltage SetPotentiometer = Output over voltage SetPush button switch = over voltage, overtemperature reset

NOTE: DON'T ALTER THE SETTING OF INDIVIDUAL SM1000 MODULES,AS THIS WILL EFFECT THE PARALLEL OPERATION.

GENERAL DATA

Operating temperature 0 Deg. C to +60 Deg. C.

Derating 2.5% / Deg. C above +40 Deg. C.

Storage temperature -20 Deg. C to +70 Deg. C.

Humidity 90% without condensation.

Cooling Fan cooled with air exhaust at the rear.

Ground Isolation Against Input 2500VDCAgainst Output 1400VDC

NOTE: Before HV test disconnect 'Y' Caps from the Earth. (Factorytest under controlled conditions.)

Connector DIN rail mounted terminals for input aswell as output and alarm.

Dimensions& Weight

SM1000 Module :- 212mm(W) x 128.5mm(H) x 327mm(D) 6KgSM1000 :- 19’’(482.6mm) x 4U (177mm) x (450mm) 17KgSM2000 :- 19’’(482.6mm) x 4U (177mm) x (450mm) 23KgSM3000 :- 19’’(482.6mm) x 7U (310mm) x (450mm) 34KgSM4000 :- 19’’(482.6mm) x 7U (310mm) x (450mm) 40KgSM5000 :- 19’’(482.6mm) x 10U (444mm) x (450mm) 52KgSM6000 :- 19’’(482.6mm) x 10U (444mm) x (450mm) 58Kg

C H A P T E R 2

Installation

Unpacking

Unit is packed in a cardboard box, which may be reused for storageof the Unit. Unpack the box carefully and check for damaged parts insidethe box or external damages to the unit during transport. Inform carriersif damages are found and also insurance agency.

Pre inspection

Remove top cover using rear panel screws and look for damagesinside the Unit and make sure there are no loose parts or screws in theunit before proceeding further.

Location

The power supply/charger should have sufficient air inflow from thefront side and sufficient space at least 30 Cm free on the rear side for airexit.

Mounting options

Power supply/charger module is 4 -unit high 19" standard rack 450 mmdeep. It is fitted with the nylon legs at the bottom.

Electrical Wiring

The unit is wired with DIN rail mounted connector at the rear,which are screw type terminal. Input/ output and alarm can bedirectly wired through these connectors.

C H A P T E R 3

OperatingInstructions

Front Panel indications and Control

Main Control Panel:

a) 'Circuit Breaker' for turning ON/OFF the input line supply.

b) 'Toggle Switch' for toggling the charger in Float/Boost mode.

c) 'Potentiometer' for single control of the output voltage.

d) 'LED's' Green for float and red for boost indication.

e) 'Display' two 3 digit display for output voltage and currentindication.

Individual Charger Module:

a) 'ON' Green LED indicates output dc presence.

b) 'OVER VOLT' Red LED indicates output voltage beyond limit set byover VOLT potentiometer. The power output reduces to zero.

c) 'OVER TEMP' Red LED indicates excessive temperature of heat sinksinside. The output shuts off in this condition.

d) ‘ON, OFF / RESET' This switch turns ON the control supply to theunit for initial turn on of the unit. Also it resets the alarmconditions. Is pressed Unit will try to restart. If the alarm conditionpersists unit will trip again.

e) 'SET OUTPUT' The output voltage can be set by this multi-turnpotentiometer on the front panel, for increasing rotate in clockwisedirection and for reducing in anti-clockwise direction.

f) 'SET OVER VOLT' The over voltage trip setting can be altered by thismulti-turn potentiometer on the panel. For increasing rotate inclockwise direction. It is set to 145 Volts by default.

Rear Panel Connectors

Input connectors (3 way Din rail mounted power terminal for input and 2way Din rail mounted control terminals for abnormal condition alarm) arelocated on the rear panel. The right-hand side connectors are for inputand left hand side connectors near to output bus bar are for alarmconnections.Outputs are provided on bus bar terminals / Din Rail mounted powerterminal located on the left hand side of the rear panel.

Functional Description of Connectors

Input Connectors: 3 Way DIN rail mounted connector is provided at theRHS of the rear clearly marked as 'L', 'N', 'E' for live, neutral and earthconnections resp. of the input line.

Output Connectors: 2 Way Din rail mounted power terminal is providedat the LHS of the rear clearly marked for the polarity as '+' and '-' foroutput positive and negative connections resp.

For high current application bus bars are used instead of Din rail powerterminal.

3 Way DIN rail mounted connector is provided at the RHS of the rearclearly marked as 'P' , 'NO’ & ‘NC’ for the extension of the abnormalcondition alarm relay contacts at the rear.

Turn On procedure

Connect 220 VAC source to the unit through rated fuse andswitch.Monitor the output on the terminals provided. Turn on the power. Outputvoltage will be developed to the nominal voltage 1% and is displayed onthe voltmeter provided, currentmeter will display the zero current. Also‘ON’ green led on all individual SM1000 modules will turn on.

Check the operation of the boost mode by toggling the Float/ Boostswitch. Load the unit to its maximum rated current & check the operationof current limit after exceeding the rated current. The alarm relay willchange the contact if the output falls below 85% after entering in thecurrent limit.

If the above points are as expected the unit is ready for operation.

V SET

FLOAT

BOOST

LINE1KW POWER SUPPLY / CHARGER SM1000

V A

OFF ON

SMPS-125V/7.9A

OFF

ON

OUTPUT

OVER VOLT.

SET

OVER VOLT.

OVER TEMP.

RESET

POWER SUPPLY / CHARGER 125V /7.9A

Front Panel Details of 1KW Power Supply / Charger SM1000

Fig. 3 . 1

V SET

FLOAT

BOOST

LINE3KW POWER SUPPLY / CHARGER SM3000

V A

OFF ON

SMPS-125V/23.8A

OFF

ON

OUTPUT

OVER VOLT.

SET

OVER VOLT.

OVER TEMP.

RESET


ON

OUTPUT

OVER VOLT.

SET

OVER VOLT.

OVER TEMP.

RESET


ON

OUTPUT

OVER VOLT.

SET

OVER VOLT.

OVER TEMP.

RESET


POWER

I

O

R

Y

B

Front Panel Details of 3KW Power Supply / Charger SM3000

Fig. 3 . 1

Rear Panel Details of 3KW Power Supply / Charger SM3000

Fig. 3 . 2

RALARM

Y B N E NO P NC

ALARML N E NO P NC

Rear Panel Details of 1KW Power Supply / Charger SM1000

Fig. 3 . 2

C H A P T E R 4

Maintenance

Introduction

This chapter contains the problems that may occur in the field in theevent of long use. The procedure to test the unit is explained under theproper section.

The individual is advised to use the correct procedure provided for thepurpose of operating the particular sequence to set proper voltages andcurrent.

This unit has few boards and interconnections and the reliability is veryhigh and has very little scope for complaints. We have, however, giventhe rare possible failures, which the user himself can set by following theremedies given under particular complaint.

Read the manual completely in order to understand your unitbetter.

Preventive Maintenance

Please follow the following preventive steps to ensure the properoperation of your instrument.

* Allow enough natural cooling (ventilation) around the unit.

* Avoid keeping tools, equipment etc. on the top cover.

*Keep the working area neat and clean always.

* Do not exceed the input/output limits at any time.

Complaints and Service Information

Some of the common problems that may occur and the remedy to putback the instrument in a working condition as fast as possible are givenbelow:

When the unit is not turning ON.

Check the power connections. Please make sure that the power cordconnecting to the unit is properly connected. Please also check the mainswitch. Check for any abnormal condition LED.For further help call the service personnel.

When the OV Trip LED on any of the module turns On and outputturns OFFMake the settings of the over voltage potentiometer of that module to

the maximum. Try to reset it through the reset switch provided on thefront panel.For further help call the service personnel.

When the OT Trip LED on any of the module turns On and outputturns OFF

Check the loads at the output. Check for the abnormal increase in thetemperature inside the module. Allow unit to cool down and try to resetthrough the reset switch provided on the front panel.For further help call the service personnel.

LEGEND:

BATTERIES:-

BATTERY CHARGER:-

NOTE:-

LEGEND:

BATTERY CHARGER:-

BATTERIES:-

NOTE:-

LEGEND:

UPS:-

BATTERIES:-

NOTE:-

BATTERY CHARGER:-

BATTERIES:-

NOTE:-

BATTERIES:-

BATTERY CHARGER:-

NOTE:-

UPS:-

BATTERIES:-

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