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Samlexpower SEC-1245A Owner's manual

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OWNER'S
MANUAL
Please read this
manual BEFORE
operating your
battery charger
Switch Mode,
Automatic, Lead
Acid Battery
Charger
MODELS:
SEC-1250UL
SEC-2425UL
2 | SAMLEX AMERICA INC.
OWNER'S MANUAL: Battery Chargers | Index
SECTION 1: Important Safety Precautions ...................................... 3
SECTION 2: Description & Features ................................................ 5
SECTION 3: Layout .........................................................................6
SECTION 4: Principle of Operation ................................................. 7
SECTION 5: Protections ................................................................ 14
SECTION 6: Installation ................................................................16
SECTION 7: Preparing the Charger for Operation ........................18
SECTION 8: Operation ................................................................ 25
SECTION 9: Troubleshooting ........................................................ 26
SECTION 10: Internal Fuse Ratings .................................................28
SECTION 12: Specications ............................................................ 28
SECTION 13: Warranty ................................................................... 30
DETAILED INFORMATION
For more detailed information, please view White Paper on our
website:
www.samlexamerica.com/support/white-papers
www.samlexamerica.com/support/application_notes
2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3
SECTION 1 | Important Safety Precautions
The following safety symbols will be used in this manual to highlight safety
and information:
WARNING!
Indicates possibility of physical harm to the user in case of non-compliance.
!
CAUTION!
Indicates possibility of damage to the equipment in case of non-compliance.
i
INFO
Indicates useful supplemental information.
Hazardous conditions may result if the charger is not installed or operated correctly.
Please read the following instructions to prevent personal injury or damage to the
charger.
BATTERY RELATED
• Toreducetheriskofbatteryexplosion,followtheseinstructionsandthosemarkedon
the battery.
• Neversmokeorallowanopensparkorameinthevicinityofthebatteryorthe
engine.
• ChargeonlyLeadAcidtypeofbatteries(Flooded/AbsorbedGlassMat(AGM)/Gel
Cell).DonotchargeothertypeofbatterieslikeNickelCadmium(NiCad),Nickel-Metal
Hydride(Ni-MH),Dry-Celletc.Othertypesofbatteriesmightburstcausingpersonal
injury.
• Neverchargeafrozenbattery.
• WorkinginthevicinityofLeadAcidbatteriesisdangerous.Batteriesgenerateex-
plosiveHydrogenandOxygengasesduringnormaloperation.Takenecessarysafety
precautions when installing the charger near a battery or in a battery compartment
(Followsafetyinstructionsgivenbythebatterymanufacturer).
• Neverplacethechargerdirectlyaboveorbelowthebatterybeingcharged;gasesor
uidsfromthebatterywillcorrodeanddamagethecharger.Locatethechargerasfar
away from the battery as DC cables permit. Do not install in the same compartment as
batteries.
• Usecautiontoreducetheriskofdroppingametaltoolonthebattery.Itcouldspark
orshortcircuitthebatteryorotherelectricalpartsandcouldcauseanexplosion.
4 | SAMLEX AMERICA INC.
SECTION 1 | Important Safety Precautions
• Removemetalitemslikerings,braceletsandwatcheswhenworkingwithbatteries.
The batteries can produce a short circuit current high enough to weld a ring or the
liketometalandthuscauseasevereburn.
• Ifyouneedtoremoveabattery,alwaysremovethegroundterminalfromthebattery
rst.Makesurethatalltheaccessoriesareoffsothatyoudonotcauseaspark.
CHARGER RELATED
• ThemaximumAhcapacitiesofthebatteriesmustbelimitedasfollows:
- SEC-1250UL: 500Ah
- SEC-2425UL: 300Ah
• Donotoperatethechargerinaclosed-inareaorrestrictventilationinanyway.
Installinawellventilated,cool,dryplace.
• Thechargermustnotbeoperatedinadamporwetenvironment.Whenmounting
inaboat,makesureitisnotsubjectedtobilgewatersplash.
• Donotblocktheventilationopenings/openingsforthecoolingfan.Thereshould
be at least 6 inches clearance all around the unit.
• InstallationandwiringmustcomplywiththelocalandtheNationalElectricalCodes.
It is recommended that installation may be carried out by a certied electrician.
• Wronginstallationonaboatmayleadtocorrosionoftheboat.Itisrecommended
that installation on the boat must be carried out by a boat electrician.
• DisconnecttheACinputpowertothechargerbeforeconnecting/disconnectingthe
batteriesorotherDCloadsorwhenworkingonthecharger.
• DisconnecttheACinputpowerbeforechangingthesettingoftheDipSwitches.
• Thechassisofthechargerisconnectedtotheearthgroundpinofthepowercord
plug.EnsurethattheearthgroundpinofACreceptaclefeedingthechargeris
connected to earth ground.
• Donotuseanadapter.Ifagroundingtypeofreceptacleisnotavailable,donotuse
this charger until proper outlet is installed by a qualied electrician.
• Donotoperatethechargerifthepowercordisdamaged.
4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
SECTION 2 | Description & Features
SEC-1250UL(for12Vbatteries)andSEC-2425UL(for24Vbatteries)arehighcurrent,3
StageChargers(alsocalledIU
O
U)thatdeliver50Aand25Arespectivelyforalmost75%
to80%ofthechargingcycleensuringaveryfast,safeandcompletechargingofLead
Acidbatteries.Thenomenclature“IU
O
U”isaDINnomenclatureandsigniesthe3
chargingstages–“I”forBulkChargeStage,“U
O
”Absorption/Over-chargeStageand
“U”forFloat/MaintenanceStage(underDINspecication,voltageisdesignated“U”
andcurrentisdesignated“I”.Thesubscript“
O
”in“U
O
”signiesover-charge).
FEATURES
• State-of-the-artSwitchModeTechnologyforhighefciency,light-weightandquiet
operation.
• UsercongurableACinputvoltage–120VACor230VAC,50/60Hz
• AutomaticoperationforalltypesofLeadAcidBatteries-Flooded,AGMorGelCell
• Userselectable2or3-StageautomaticchargingalgorithmwithtimedAbsorption
Stageandtemperaturecompensationensuresrapid,safeandfullreturnofcapacity
for stand-alone and loaded batteries.
• Abilitytoreducemaximumchargingcurrenttoapproximately1/2oftheratedcapac-
ityduring“HalfPowerMode”.Thisallowssafechargingoflowercapacitybatteries.
• IncludesaBatteryTemperatureSensorallowingtemperaturecompensatedcharging,
if required.
• 2banksofbatteriescanbechargedsimultaneouslywithouttheuseofanexternal
batteryisolator.Thechargingcurrentwillbesharedbetweenthetwobanksdepend-
ing upon the depth of discharge of the connected batteries.
• VoltmeterandAmmeterformonitoring
• Fancooled-fanON/OFF based on output current.
• Protectionsagainstshortcircuit,overcurrent,reversebatteryconnectionand
over-temperature.
• CanbeusedasapowersupplyorasaDCUPS(UninterruptiblePowerSupply)
when used in conjunction with a battery.
• OptionalRemoteLEDPanelModel900-RCwith10Metersofwireforremote
ON/OFFcontrolandindicationofchargingstatus.
• SafetycertiedandlistedtoULStandardUL-1564
• EMIcomplianttoFCCPart15(B),ClassB
MAXIMUM AH CAPACITY OF BATTERY TO BE CHARGED
Ifthechargersareusedtochargeveryhighcapacitybatteries,theywillbeforcedto
supplytheirmaximumratedchargingcurrentforlongertimethanthedesignedlimit
andhence,thecomponentswillbeoverstressedandarelikelytofailprematurely.To
preventprematurefailure,themaximumAhcapacitiesofthebatteriesmustbelimited
as follows:
- SEC-1250UL:500Ah
- SEC-2425UL:300Ah
6 | SAMLEX AMERICA INC.
SECTION 3 | Layout
NOTE:BothSEC-1250ULandSEC-2425ULhavethesamelayoutanddimensions
Fig. 3.1 Layout of SEC-1250UL and SEC-2425UL
4 5 6 7 8
3 2 1
9
10
11
OUTPUT SIDE
INPUT SIDE
12
13
LEGEND
1. Output connector: +, Bank 1
2. Output connector: +, Bank 2
3. Output connector: –, Common
4. Jack for Temperature Sensor
5. Green LED: Indicates “Half Power
Mode” is ON
6. Jack for optional Remote LED
Panel Model No. 900-RC
7. DIP switches for mode selection
8. Push Switch for Half Power Mode:
Pressed ON; Released OFF
9. Power ON/OFF switch
10. AC power cord inlet
11. Grille protected opening for
cooling fan
12. Voltmeter
13. Ammeter
TOP VIEW
3
2
1
11
10
6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
SECTION 4 | Principle of Operation
i
INFO
Forcompleteunderstandingofworkingofbatterychargers,understandingof
operationofLeadAcidbatteriesisdesirable.
Fordetailedinformationonconstruction,workingandapplicationofbatteries,
pleaserefertoApplicationNotetitled“LeadAcidBatteries–Constructionand
Application”atthefollowinglinktoSamlexAmerica,Inc.website:
www.samlexamerica.com/support/application_notes.aspx
BATTERY CHARGER IS A CURRENT LIMITED DC POWER SUPPLY
ThechargerisacurrentlimitedDCpowersupplythatconverts120/230VAC,50/60Hz
toregulatedDCvoltagesandlimitsthemaximumoutputcurrentasfollows:
Model No. Current Limit
Constant
Voltage at Bulk
Stage “I”
Constant
Voltage at
Absorption
Stage “U
0
”
Constant
Voltage at
Float Stage
“U”
SEC-1250UL 50A 13.5VDC
14.0VDCor
14.4VDC
13.5VDC
SEC-2425UL 25A 27VDC
28.0VDCor
28.8VDC
27VDC
Thespeciedoutputvoltageofthechargerduringparticularchargingstageisheld
constanttillthecurrentlimitvalueisreached.WhenthebatteryorDCloadtriestodraw
current>thecurrentlimitvalue,thechargerlimitsthecurrenttothecurrentlimitvalue
andtheoutputvoltageofthechargerdropsandisnolongerconstant.Whenthechar-
gerisconnectedtoabatteryandisincurrentlimitcondition,theterminalvoltageof
thechargerwillbeclampedtotheactuallowerintrinsicterminalvoltageofthebattery
(assumingthechargerisveryclosetothebatteryandthereisnovoltagedropinthe
wiresconnectionthechargertothebatteries).
BATTERY IMPEDANCE AND CHARGING CURRENT
Theinternalimpedanceofahealthybatteryisverylow-intensofmilliOhms(The
impedance is higher in discharged condition due to Lead Sulfate formation and reduces
whenthebatteryisfullycharged–LeadSulfategetsfullyconvertedtoLeadandLead
Dioxide).Averageimpedancemaybeassumedas20milliOhmor0.02Ohm
Whenthechargerisdeliveringaconstantvoltage(isnotincurrentlimitcondition),the
charging current drawn by the battery can be roughly calculated as follows:
Charging current = (Charger Voltage - Intrinsic battery voltage) ÷ Internal resistance (0.02 Ohm)
8 | SAMLEX AMERICA INC.
SECTION 4 | Principle of Operation
Forexample,whenSEC-1250ULisintheBulkChargeStage1,itsoutputvoltageisset
at13.5VDC.Whenabatterydischargedtosay10.5Vischarged,itwilltrytodrawvery
largecurrent=(13.5V-10.5V)÷Internalresistance(0.02Ω)=150A.SEC-1250ULwill,
however,limitthiscurrentto50A.
CHARGING STAGES
The battery is charged in 3 stages:
• STAGE1-BULKSTAGE(“I”Phase),
• STAGE2-ABSORPTIONSTAGE(“U
O
”Phase)and
• STAGE3-FLOATSTAGE(“U”Phase)
The3chargingstagesandassociatedChargingCurvesforSEC-1250ULaregivenatFig-
ure 4.1 and for SEC-2425UL at Fig. 4.2
Figure 4.1 Charging Curve - SEC-1250UL
* Stage 2 time for 4 or 8 hours.
Voltage
curve
Current
curve
10% of
current
capacity
of charger
(5A ± 0.5A)
80% of
current
capacity
of charger
(40 Amps)
Time, Hours
14.4V
13.5V
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
55
50
45
40
35
30
25
20
15
10
5
0
AMPS VO LT S
Fig xxx - SEC-1250UL Charging Curves (Absorption 14.4V, Float 13.5V)
50A
Stage 1
“I Phase”
Stage 2*
“Uo Phase”
Stage 3
“U Phase”
B1 C1
D1
E1
B2 C2 D2
E2
A1
A2
8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
SECTION 4 | Principle of Operation
Voltage
curve
28.8V
27V
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
27.5
25.0
22.5
20.0
17.5
15.0
12.5
10.0
7.5
5.0
2.5
0
AMPS V O LT S
Fig xxx - SEC-2425UL Charging Curves (Absorption 28.8V, Float 27V)
B1 C1
D1
E1
B2 C2 D2
E2
25A
A1
A2
* Étape 2 temps de 4 ou 8 heures.
10% de la
capacité
actuelle
du chargeur
(3A ± 0,5A)
80% de
la capacité
actuelle du
chargeur
(20 ampères)
Temps, Heures
Étape 1
“Phase I”
Étape 3
“La Phase U”
Étape 2*
“La Phase Uo”
Fig. 4.2 Charging Curve for SEC-2425UL
i
INFO
Please note the following important information related to the Charging Curves
shown in Figs 4.1 and 4.2 above:
1.1 Terminal Voltage reading on no load and on load: The output terminals of the
chargerconsistofonecommonNegativeterminal(3)andtwoRedPositiveterminals
(1,2)forchargingtwobanksofbatteries.EachofthetwoPositiveterminalsofthe
twobankshasSchottkyDiodeinseriesforisolation.Theseisolatingdiodeshavea
currentdependentforwardvoltagedropVfrangingfrom0.2to0.3V(at0.1A)to
0.6V(at50A).Inaddition,therewillbeadditionalforwarddropVbacrossthebulk
resistance of the diode and this drop will also increase with increase in charging
current. Please note that the forward voltage drops Vf and Vb occur only when cur-
rent ows through the diode.
1.2TheFloatandAbsorptionvoltagesaretightlyregulatedbeforetheisolating
diodes.However,thevoltagesavailableattheterminalsofthetwobankswillvary
withthevalueofthechargingcurrentbecauseofthecurrentdependentforward
voltagedropVfandbulkresistancedropVb.TheFloatVoltagebeforethediodesis,
10 | SAMLEX AMERICA INC.
SECTION 4 | Principle of Operation
therefore,set0.2to0.3Vhighertocompensatefortheforwarddropsduringoat
conditionwhenthechargingcurrentwouldhavedroppedtolessthan1A.Hence,
theoutputvoltageattheterminalsofthetwobanksatnoload(nothingconnected
totheterminalsofthebanks)willread0.2to0.3Vhigherbecausethereisnofor-
wardvoltagedropasthereisnocurrentowthroughthediodes.Thevoltagesare
speciedwithrespecttocharging/loadcurrentasfollows:
AbsorptionStage(“U
O
”Phase)of14.4/14VforSEC-1250UL At5A+/-0.5A
AbsorptionStage(“U
O
”Phase)of28.8/28VforSEC-2425UL At3A+/-0.5A
FloatStage(“U”Phase)of13.5VforSEC-1250UL At0.1A
FloatStage(“U”Phase)of13.5VforSEC-2425UL At0.1A
1.3 Pleasealsonotethattheoutputvoltageatthetwobanksmaydifferbetween
0.2to0.6Vdependinguponthedifferentvaluesofthechargingcurrentbeingdeliv-
eredthrougheachasaresultofdifferentvaluesofvoltagedropsVfandVb.
2.1 Standard Temperature Conditions:Thechargingvoltagesshownpertaintobat-
teryelectrolytetemperatureof77°F(25°C)
3.1 Charger / Battery Voltage / Current Values:Whenthebatteryisconnectedto
thechargerandthechargerisinONcondition,thevoltageatthecommoncharger
/batteryterminalswillbetheactualbatteryterminalvoltagecorrespondingtoits
stateofchargeONLYwhenthechargerisin“currentlimitcondition”andissup-
plying50AforSEC-1250ULand25AforSEC-2425UL.WhenthechargerisNOTin
“currentlimit”conditionandissupplying<50AforSEC-1250ULor<25Afor
SEC-2425A,itsterminalvoltagewillbenearlyregulatedandwillbenearlyequalto
thesetBulk/FloatVoltageof13.5VforSEC-1250UL(27VforSEC-2425UL)ornearly
equaltotheAbsorptionVoltageof14.4/14VforSEC-1250UL(28.8V/28VforSEC-
2425UL).Undertheseconditions,thebatteryterminalvoltagewillalsobeat13.5
(27V)or14.4/14V(28.8V/28V)although the actual intrinsic terminal voltage of the
battery corresponding to its State of Charge at that point of time will be lower.
3.2 Thevoltagecurveshowsthevoltageatthechargeroutputterminals,whichwill
bethesameasthevoltageatthebatteryterminals(assumingthatthereisnovolt-
agedropalongthewiresconnectingthechargertothebatteries)
3.3.TheCurrentCurveshowsthecurrentbeingdrawnbythebattery
10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11
SECTION 4 | Principle of Operation
STAGE 1- BULK CHARGE STAGE (“I” PHASE)
InthisstageSEC-1250ULoutputsvoltageof13.5VDCandSEC-2425Aoutputs27V.
ThefollowingexplanationisforSEC-1250UL.ExplanationforSEC-2415ULwillbe
samebutthevoltagevalueswillbe2timesandcurrentvalueswillbehalfascompared
to SEC-1250UL.
NOTE: For explanation purpose, it is assumed that the battery is deeply discharged
to around 10.5 / 21V when charging is initiated.
Whenthechargerisswitchedon,thebatterywilltrytodrawverylargecurrent=
(13.5V-10.5V)÷Internalresistance(0.02Ω)=150Awhichwillbemuchhigherthanthe
currentlimitvalueof50A.Thechargerwillentercurrentlimitcondition(pointA2),
itsinternalvoltagewilltrytodropbutwillbeclampedtotheterminalvoltageofthe
batteryi.e.10.5V(pointA1).Thebatterystartschargingatconstantcurrentof50A(Sec-
tionA2-B2)anditsintrinsicvoltagestartsrisingalmostlinearly(SectionA1-B1).When
itsintrinsicvoltageapproaches13.5V,thecurrentdrawnbythebatterywillreduceto
<50A.Atthispoint(B2),thechargerwillexitcurrentlimitandwilloutputaconstant
voltageof13.5V(pointB1).Asthebatterychargesfurtherunderconstantvoltageof
13.5V(SectionB1–C1),itsintrinsicvoltagerisesfurtheranditscurrentstartstotaper
down(SectionB2–C2).Thecurrenttapersdownbecausetheintrinsicbatteryvoltageis
risingandthedifferentialvoltagebetween13.5Vofthechargerandintrinsicvoltageof
thebatteryisreducingthereby,lessercurrentisdrivenintothebattery.Taperingcharge
isprovidedatthistransitiontoreducesurfacechargeeffecttoensurethatthecharge
slowlydiffusestotheinternalthicknessoftheplatesandpreventsovercharging.When
thechargingcurrenttapersdownto80%oftheratedcapacityofthecharger(40Afor
SEC-1250ULand20AforSEC-2425UL)atpoint“B2”,thechargertransitionstothenext
Stage2-AbsorptionBoostStage(“U
O
”Phase)
Charging Characteristics During This Stage Are As Follows:
• Batteryvoltagerisesslowlyandalmostlinearly(itwillstartrisingsharplyat
thebeginningofthenextAbsorptionStage2).
• TheentirechargingcurrentisusedtoconvertLeadSulfatetoSpongeLeadat
theNegativeplatesandtoLeadDioxideatthePositiveplates.
• Thereisnogassingandthechargingefciencyishigh-around91%.
• Therestoredcapacityinthisstageisinverselyproportionaltothechargingrate
(duetoPeukertEffect).Thismeansthatasthechargingrateisincreased,the
capacityrestoredreduces.Thisstagerestores60%ofcapacityatchargingrate
ofC/5,70%to75%capacityatchargingrateofC/10and85%to90%of
capacityatchargingrateofC/20
• RedLEDmarked“IPhase”willbelitontheoptionalRemoteControl
Model900-RC
12 | SAMLEX AMERICA INC.
STAGE 2 – ABSORPTION STAGE (“U
0
” PHASE)
Duringthisstage,thechargeroutputsconstantvoltageof14V/14.4VforSEC-1250UL
and28V/28.8VforSEC-2440UL.Aschargingproceeds,thereisafairlysharpriseinthe
batteryvoltageasgassingstarts.Gassingandfastriseofbatteryvoltagecontinuesto
restore the balance of the capacity till charging is completed.
TheChargerTransitionsToAbsorptionStage(“U
O
”Phase)AtPoint“C”.
Assoonasthechargertransitionstothisstage,auserselectable4Hr/8HrTimeris
startedwiththehelpofDIPSwitches(7)(Seepage22under“Selectingtimeforstage
2-AbsorptionStage”).ThisTimerdecidesthemaximumdurationofoperationinthis
stageandsubsequenttransitiontothenalconstantvoltageFloatStage3atpoint“E”.
The duration of operation in this stage is also determined by another condition where
thetransitiontothenextFloatStageatpoint“E”occurswhenthechargingcurrent
reducesto10%ortheratedcapacityi.e.5A+/-0.5AforSEC-1250ULand3A+/-0.5Afor
SEC-1225UL.Thecondition,whichoccursearlier,controlsthetransition
Atthetransitionpoint“C”,thechargerwilloutputahigherconstantvoltage,whichis
abovetheGassingVoltagetoensurethatthebatteryisfurther,chargedtofullcapacity
withoutovercharging.Thevalueofthisvoltagewilldependuponthetypeofbatteryor
chargingstagesselected(Thetypeofbatteryandchargingstagesareselectedwiththe
helpofDIPSwitches(7)-SeeSection7under“DIPSwitchSetting”onpage21):
• 14.4V(SEC-1250UL)or28.8V(SEC-2425UL)whenFlooded/AGM
battery is selected
• 14V(SEC-1250UL)or28V(SEC-2425UL)whenGelCellbatteryisselected
• 13.5V(SEC-1250UL)or27V(SEC-2425UL)whenloadedbatteryis
selected(2stagecharging)
However,thisconstantvoltageisnotseenimmediatelybecausethechargerenterscur-
rentlimitassoonasitenterspoint(C2).Asthechargervoltagehasbeenincreased,the
batterywilltrytodrawhighervalueofcurrentwhichwillbeequaltothedifference
betweenthishighervoltageandtheactualintrinsicvoltageofthebatterydividedby
theinternalresistanceofthebattery(.02Ohm).Thevalueofthiscurrentatthetransi-
tionpoint(C2)willbehigherthanthecurrentlimitvalueforcingthechargertoenter
currentlimitconditiononceagain.Asthechargerisincurrentlimitcondition,itdoes
notregulateitsoutputvoltage.Thevoltageatthechargerterminalsistheactualinter-
nalbatteryvoltageatthatpoint(C1).Onceagain,thebatterystartschargingfurtherat
themaximumratedconstantcurrentof50AforSEC-1250UL/25AforSEC-2425UL(C2to
D2).Thebatteryvoltagealsostartsrisingfurther(C1toD1).
Atpoint(D2),thechargingcurrentreducestolessthanthecurrentlimitvalueof50A
forSEC-1250UL/25AforSEC-2425ULandthechargernowexitscurrentlimitedconstant
currentmodeandentersconstantvoltagemodeof14V/14.4VforSEC-1250ULand
28V/28.8VforSEC-2440UL(pointD1).(Pleasenotethatthevoltageof14V/14.4Vor
SECTION 4 | Principle of Operation
12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13
SECTION 4 | Principle of Operation
28V/28.8VatboththechargerandbatteryterminalsistheconstantAbsorptionVolt-
agebeingputoutbythecharger.Theintrinsicvoltageofthebatteryisstilllowerthan
thisvoltageasthebatteryisstillnotfullychargedatthistransition).Astheintrinsic
voltageofthebatteryrisesfurther,thechargingcurrentstartstaperingdown(section
D2toE2).Taperingchargeisprovidedatthistransitiontoreducesurfacechargeeffect
toensurethatthechargeslowlydiffusestotheinternalthicknessoftheplatesand
preventsovercharging.
Whenthe4Hr/8HrTimerrunsoutorwhenthechargingcurrenttapersdownto10%
oftheratedcapacityofthecharger(5A+/-0.5AforSEC-1250ULand3A+/-0.5AforSEC-
2425UL)atpoint“E2”(whicheverisearlier),thechargertransitionstothenextStage3
-ConstantVoltage,FloatorMaintenanceChargeStage(“U”Phase)
NOTE: Thethresholdofcurrentforchange-overbetweentheConstantOverchargeVolt-
age,TimedVoltageAbsorption/BoostStage(“U0”Phase)&theFloat/Maintenance
ChargeMode(“U”Phase)aredifferentasfollows:
SEC-1250UL SEC-2425UL
From“Uo”Phaseto“U”Phase 5A+/-0.5A 3A+/-0.5A
From“U”Phaseto“Uo”Phase 10A+/-1A 6A+/-1A
Charging Characteristics During This Stage Are As Follows:
• TheAbsorptionStage(“U
O
”Phase)feedsadditional35%to55%ofthecapacitythat
addsuptoatotalchargedcapacityofaround115%totakecareofaround15%loss
of charging efciency.
• OrangeLEDmarked“U
O
”PhaseontheoptionalRemoteControl900-RCwillbelit
STAGE 3 - CONSTANT VOLTAGE, FLOAT OR MAINTENANCE
CHARGE STAGE (U PHASE)
Duringthismode,thechargeroutputsaconstantvoltage"U"=13.5V(SEC-1250UL)or
27V(SEC-2425UL).Thishelpsinmaintainingfullcapacityofthebatteryandalsopro-
videsreplacementchargetoovercomeselfdischargeofthebattery.Thebattery
canremainconnectedinthisstageindenitelywithouttheriskofdischarging.
Charging characteristics during this stage are as follows:
GreenLEDmarkedFloatStage(“U”Phase)ontheoptionalRemoteControl
900-RCwillbelit.
14 | SAMLEX AMERICA INC.
SECTION 4 | Principle of Operation
!
CAUTION!
3stagechargingisrecommendedforchargingstand-alone,unloadedbatteries
(thereisnoloadconnectedtothebatterywhenitisbeingcharged).Ifaload
isalsoconnectedsimultaneously,apartofthecharger’soutputcurrentwill
bedivertedtothisload.Thus,thechargermayremainlockedinStage2ifthe
currentdrawnbytheloadismorethanthepresetvalueofthresholdcurrent
determiningchangeoverfromStage2toStage3.Thiswillleadtoover-charg-
ing and loss of electrolyte.
Forchargingabatterywhenaloadisalsoconnectedsimultaneously,Stage2
voltageshouldbesameasStage3.Select“LoadedBattery”withthehelpof
DIPSwitchesmarked“Mode”(7)-SeeSection7under“DIPSwitchSetting”on
page 21.
SECTION 5 | Protections
The charger has the following protections:
SHORT CIRCUIT SHUT DOWN
Incaseofashortcircuitontheoutputside,theoutputofthechargerwillbeshutdown.
AnothersymptomofshortcircuitshutdownisthatthefanwillbeONtilltheunitis
resetorswitchedOFF.OntheoptionalRemoteControl900-RC,GreenLEDmarked
"Power"andRedLED"IPhase"willbelit.Thechargerwillbelatchedinthisshutdown
conditionandwillNOTrecoverautomaticallyevenaftertheshortcircuitconditionis
removed.Toreset,theACinputpowerON/OFFswitchatthebackoftheunithastobe
switchedOFFandONagain.
OVER LOAD CURRENT LIMITING
Thecurrentdrawnbytheloadisautomaticallylimitedtoamaximumof50Afor
SEC-1250UL(25A+/-1Ain“HalfPowerMode”)and2AforSEC-2425UL(12.5A+/-1A
whenin“HalfPowerMode”).Iftheloadtriestodrawahighercurrentthantheselim-
its,theoutputvoltageoftheunitwillstarttodrop.Theunitwillautomaticallyrecover
whentheoverloadconditionisremoved.
REVERSE BATTERY CONNECTION – DC SIDE FUSES WILL BLOW
TheoutputisinternallyfusedontheDCside-2x30AfusesforSEC-1250ULand2X
20AfusesforSEC-2425UL.Incase,thepolarityofthebatteryconnectionisreversed,the
fuse(s)willblow.AnothersymptomofblownfuseonDCsideisthatthefanwillbeON
tilltheunitisswitchedOFF.OntheoptionalRemoteControl900-RC,GreenLEDmarked
"Power"andRedLEDmarked"IPhase"willbelit.
14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15
SECTION 5 | Protections
COOLING
Thechargeriscooledbyconvectionandinaddition,hasafanforforcedair-cooling.
The operation of the fan is controlled by the current supplied by the charger and will be
switchedONandOFFautomaticallyasfollows:
SEC-1250UL SEC-2425UL
SwitchONcurrent 10A+/-1A 6A+/-1A
Switch OFF current 5A+/-0.5A 3A+/-0.5A
NOTE:Oncethefanswitchesonatthespeciedcurrentthreshold,itwillswitchoffat
alowerthreshold.Forexample,thefaninSEC-1250ULswitchesONat10Abutswitches
OFFat5A.ThisistopreventthefanfromoscillatingbetweenONandOFFconditions
duetominoructuationsinloadcurrent
OVER TEMPERATURE SHUTDOWN
!
CAUTION!
Keepthechargerinawellventilated,coolandopenarea.DONOTBLOCKTHE
VENTHOLESonthesidesorthedischargeopeningsofthecoolingfan.Keepat
least 6” clearance on all sides
In case the fan fails or if the cooling is not adequate due to higher ambient tempera-
ture,inadequateaircirculationorblockageofairventilationopenings,thetemperature
insidetheunitwillrise.Atemperaturesensorismountedoninthewindingsofthe
powertransformer.At105°C+/-5°Cthethermalsensorwillactivateandshutdownthe
outputvoltageofthecharger.ThefanwillbeON.OntheoptionalRemoteControl
900-RC,GreenLEDmarked"Power"andRedLEDmarked"IPhase"willbelit.The
chargerwillbelatchedinthisshutdownconditionandwillNOTresetautomatically
evenaftertheunithascooleddown.Toreset,theACinputpowerON/OFFswitchatthe
backoftheunithastobeswitchedOFFandONagain.
PROTECTION AGAINST TRANSIENTS / SURGES IN THE AC INPUT
Inanumberoflocations,theAClineinputisnotcleanandmaycontainhighvolt-
agetransients/surges.Topreventdamagetotheinternalcomponentsagainstthese
unwantedhighvoltages,thechargerusesaMOV(MetalOxideVaristor)forprotection.
Ifsurge/transientvoltagehigherthanapproximately170VACin120VMode/340VAC
in230VACModeappearintheACinput,theMOVwillconductandwillblowtheAC
side fuse.
16 | SAMLEX AMERICA INC.
SECTION 6 | Installation
INSTALLATION DIMENSIONS
Installationdimensionsaregivenbelow.DimensionsaresameforSEC-1250ULand
SEC-2425UL.
16 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 17
SECTION 6 | Installation
LOCATION, MOUNTING AND SAFETY
Thechargerisrequiredtobeinstalledinasafe,wellventilatedanddrylocation.
Pleaseseethedetailsgivenunder“ImportantSafetyPrecautions”.Thechargercanbe
mountedhorizontallyorvertically.Whenmountingverticallyonawallorabulkhead,
pleaseensurethattheaxisofthefanrotorishorizontali.e.thefanexhaustopening
shouldfaceleftorrightbutNOTfaceupordown.
WARNING!
Mountingtheunitverticallyonaverticalsurfacewiththefanopeningfacing
upordownisNOTallowedforsafety.Thisistopreventfallingofobjectsinto
the unit through the fan grille when the fan opening faces up. If fan opening
facesdown,hotdamagedcomponentsmayfallout.
OUTPUT CONNECTORS
Connectorswithtubular,screwdowntypeofterminalsareusedforoutputconnection.
Thediameterofthetubularholeoftheconnectoris8mm(0.31inches).Twopositive
outputconnectors(1,2)areprovidedforconnectingtothePositiveterminalsofthe2
banksofbatteries.Onecommonconnector(3)isprovidedfortheNegative
connection.
TERMINAL LUGS FOR CONNECTION TO THE CHARGER
Forrmconnectionwhenusingstrandedwire,crimp/solder“pin”styleterminallugs
onthechargerendoftheDCwiresusedforconnectingtothebattery/otherDCloads.
3piecesof“pin”styleterminallugshavebeenprovidedasfollows:
• ForSEC-1250UL WillaccommodateuptoAWG#4wire
• ForSEC-2425UL WillaccommodateuptoAWG#8wire
WIRES
Toavoidpolarityerrorsandpossibledamage,neverusewiresofonlyonecolor.UseRed
insulatedwire(s)forPositiveconnection(s)andBlackforNegativeconnection(s).
RecommendedDCwiresizesaregivenbelow(Basedonavoltagedropof2%).The
lengthinfeetisthelengthofthepairofthepositiveandnegativeDCwiresfromthe
chargertothebattery/otherDCloads.
Distance From Battery SEC-1250UL SEC-2425UL
Up to 6 ft. AWG#6 AWG#10
6 to 10 ft AWG#4 AWG#8
10 to 20 ft. AWG#1/0 AWG#6
TERMINATION OF WIRE ENDS
Forrmconnectionwhenusingstrandedwire,wireendsfortheconnectiontothe
chargershouldbeterminatedwithpintypesoflugsthathavebeenprovided.
18 | SAMLEX AMERICA INC.
SELECTING AC INPUT VOLTAGE
Thechargerispre-settooperatefrominputACvoltageof120VAC,60Hz.Tooperate
thechargerfromACinputvoltageof230VAC,50Hz,changetheinternalsettingas
follows:
1.Removethesideplatethathasthepowercordentrybyunscrewing4screws
2.RemovetheVoltmeterandtheAmmeteronthetopcentralplatebypryingupthe
bottomedgesofthemeterswithabroad,atscrewdriverandbypushingthemeters
upfromthebottomoftheplate(thesearesnaptted).Removetheconnectingwires
andmarkthem.Notethepolarityforconnectingbackinproperpolarity.Themeter
terminalsaremarkedPositive(+)andNegative(-).ThickerwiresarefortheAmmeter
andthinnerarefortheVoltmeter
3.Gentlyslidethecentertopcoverplateout.Noteandmarkitsorientationfor
correct re-tting
4.LocateYellowloopofjumperwirewithquickfemaledisconnect.Inthepre-set
120VACcondition,thisjumperwireisshortingthemaleverticalpinsmarked“C”and
“D”and“115V”.Pullanyoneendofthisfemaledisconnectupwardstodisconnect
shortingbetween“C”and“D”.Insulatethisendwithinsulatingtape.Theunitisnow
setfor“230VAC”
5.The120VACversionhasasoldered12AfuseontheACside.Whenconverting
120VACversionunitfor230VACoperation,thereisnoneedtoreplacethe12Afuse
6.ReplacetheACplugofthepowercordwithasuitable3pingroundedplugtomate
withthe230VACoutlet.
!
CAUTION!
Thenewplugshouldhave3polesi.e.Line(L),Neutral(N)andEarthground.
Color code for the power cord conductors is:
- Line(L)-Black
- Neutral(N)-White
- Earthground-Green
CONNECTING THE BATTERIES OR OTHER DC LOADS
AsshowninFig.7.1and7.2(page19),theoutputofthechargerhasacommonNega-
tive(-)connectorand2Positiveconnectorsforconnectionof2banksofbatteries.Each
Positiveconnectorhasitsowninternalisolatingdiode,whichworksasabatteryisolator.
Ifmorethanonebankofbatteriesisconnected,thesewillbechargedatthesametime
aslongastheACpowerisavailabletothecharger(themaximumchargingcurrentof
50AofSEC-1250ULand25AofSEC-2425ULwillbesharedamongtheconnectedbanks
ofthebatteriesdependingupontheirdischargedstates).IncasetheACpowerfails
orifthereisnooutputfromthecharger,theisolatingdiodeswillpreventcharging/
dischargingamongthebatteriesconnectedtothebanks.
SECTION 7 | Preparing the Charger for Operation
18 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 19
SECTION 7 | Preparing the Charger for Operation
Starter
Battery
Auxilary /
House
Battery
Battery 4 Battery 3 Battery 2 Battery 1
Negative
Wire “B”
Positive
Wire “A”
Fig 7.1 Connecting 2 separate battery systems to 2 separate banks
Fig. 7.2 Connecting bank of paralleled batteries to single bank
20 | SAMLEX AMERICA INC.
Inasinglebatterybank,twoormorebatteriesmaybeconnectedinparalleltoincrease
theirAHcapacity.Thesewillbedischargedandchargedasasinglebatterybank.Inthis
case,theparalleledbankofmultiplebatteriesistobeconsideredasasinglebankand
connectedtoanyoneofthe2banksofthechargerasshowninFig.7.2forbankof4
batteries.Forproperchargingofallthebatteries,pleaseensurethatthePositivewire
“A”fromthechargerisconnectedtothePositiveterminaloftherstbattery(Battery
1)andtheNegativewire“B”isconnectedtotheNegativeterminalofthelastbattery
(Battery4).Thiswillensurethefollowing:
• Resistanceoftheinterconnectingcableswillbebalancedandtheindividualbatteries
will see the same series resistance
• Alltheindividualbatterieswillbechargedatthesamechargingcurrentandthuswill
be charged to the same state of charge
• Noneofthebatterieswillseeanover-chargecondition
WhenconnectingasinglebatteryorothersingleDCload,itcanbeconnectedtothe
commonNegativeandanyoneofthe2PositiveterminalsasinFig.7.1.
CHARGING MORE THAN ONE BANK OF BATTERIES
!
CAUTION!
Whenchargingmorethanonebankofbatteriesatthesametimeusing3Stage
Charging,ensurethatthebatteriesinthebanksareinasimilardischargedcon-
dition.Ifonebankiscompletelydischargedandanotherisalmostfullycharged,
thebankthatisfullychargedwillbesubjectedtooverchargeconditionduring
thetimewhenthechargerremainsinStage2(“Uo”Phase)forchargingthe
completelydischargedbank.
If2banksofbatteriesarerequiredtobechargedandtheyareatdifferent
dischargedconditions,select“LoadedBattery”(2StageCharging)withthehelp
ofswitchesS1andS2ofthesetof4DIPSwitches(bothS1&S2inoffcondition)
-Seeunderheading“DipSwitchSetting”onpage21.
SELECTING TYPE OF BATTERY AND CHARGING STAGES
Stage3FloatStage(“U”Phase)voltageandStage2AbsorptionStage(“Uo”Phase)volt-
agearedifferentfordifferenttypesofLeadAcidBatteries.
3Stagecharging(Stages1,2and3)isrecommendedwhenchargingstandalone,un-
loadedbattery(Thebatteryhasnoloadconnectedtoitwhenitisbeingcharged).
Whenthechargerisusedtochargeabatteryandsimultaneouslysupplyanexternal
load,thevoltagelevelofStage2isrequiredtobesettothesamelevelasthevoltageof
Stage3topreventover-charging.Effectively,thebatterywillbechargedin2stagesonly
SECTION 7 | Preparing the Charger for Operation
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