ST - III Series POWER SUPPLIES USER MANUAL
Contents
1. oO O m on Battery Isolate nput E L1 F1 jes m gt Load 1 lt L1 TOP F2 M EE D Load 2 lt L1 F3 0 f mum Load3 lt L1 F4 bea m gt Load4 lt CAUTION T V Ext must be supplied from t a Fused F Ext external aa mma gt Load5 C voltage l i L3 F6 gt Loads lt L4 t F7 j m gt Load7 C L5 F8 m gt Load 8 _ To L VBATT VBATT FBATT m gt C m RETE TRE WV Ext 7 arti cas Ioa ne ve ve terminals terminals Plus Vext input Page 5 of 11 Issue D ST Ill Series Power Supplies USER INSTRUCTIONS Cabling sizes DC cables must be sized to carry the maximum full load current and not exceed the system volt drop requirements The following cable sizes are recommended Current AWG mm 0 10A 18 1 0 10 20A 14 3 0 20 30A 10 5 5 Where cables pass through any part of a metal panel or cover ensure that a cable gland or bush is fitted to the hole Battery Connection Procedures Battery should be connected as per the following steps Turn power supply off and all 12 volt equipment connected to power supply Connect positive battery terminal to Batt VE power supply terminal Connect negative battery terminal to Batt VE power supply terminal or negative chassis ground If battery is connected to chassis ensure a connection exist from chassis to Batt VE terminal of power supply Battery Disconnection Procedure2. 24 hour timer Vfloat No mains input voltage is Float charging mode with Vfloat No detected no mains input voltage mains input detected set 1 hour timer Vstore No mains input voltage is Float charging mode with Vfloat No Periodic _Vboost detected No mains input voltage is detected no mains input voltage detected set 1 hour timer Float charging mode with no mains input voltage detected set 1 hour timer mains input Vfloat No mains input Page 9 of 11 Issue D ST Ill Series Power Supplies USER INSTRUCTIONS Present Output Conditions Required to Onecadonall Staite New Output Set Set Voltage Enter Operational State P Voltage Vfloat No Mains Mains input voltage was Loss of mains boost Vboost Input detected after being absent charging mode active after for more than 1 hour resumption of mains input supply set 15 minute boost timer Vboost No Mains Mains input voltage was Loss of mains boost Vboost Input detected this condition charging mode active after must also reset the 15 resumption of mains input minute boost period supply set 15 minute boost timer Vboost No mains input voltage is Boost charging mode while Vboost No detected no mains is detected Mains Input Vfloat Mains input voltage was Battery storage mode set Vstore present for more than 24 24 hour timer hours Periodic Vboost Periodic boost voltage Battery storage mode set Vstore Vstore timer has timed
3. over nominal input voltage operating range Output Current ST20 II 20A Continuous load battery current ST35 II 35A Continuous load battery current Factory Set Voltage Load Regulation Output Ripple Voltage Over Voltage Protection 13 65V 0 1V Vfloat lt 2 lt 150mV lt 17V Over Current Protection Battery Current Limit ST20 II 20A to 25A load battery current ST35 H 35A to 38A load battery current 10A 1A ST20 1 15A 1A ST35 I Battery Connect 10 50 0 2V Input Mains not present and first power up Connect Disconnect Connect 11 70 0 2V Input Mains not present and not first power up Connect 11 50 0 2V Input Mains present Disconnect 10 0 0 2V Battery Trickle 0 8A Charge Battery Drain lt 2mA Efficiency gt 84 Cooling Fan Cooling fan on temperature of Transformer 95C 3 degrees Operation ST35 II Only Cooling fan off temperature of Transformer 75C 3 degrees Ambient 0 C 50 C Weight lt 2kg Standards Safety AS NZS 60335 1 AS NZS 60335 2 29 amp AS NZS 61558 EMC CISPR 22 class A Compliance ERAC ACMA RCM Page 8 of 11 Issue D ST Ill Series Power Supplies USER INSTRUCTIONS Battery Management To maintain the battery in a good state of health an intelligently controlled charging algorithm is used The purpose is to ensure that the correct voltages are applied to the battery terminals at the ap
4. ST lil Series POWER SUPPLIES USER MANUAL Introduction These instructions detail the installation and operation requirements for the ST20 III amp ST35 III power supplies These have been designed for operation in RV s providing a DC power system with optional battery back up The units operate from 240Vac and provide an isolated 13 65Vdc output at 20A and 35A respectively for powering the load and charging of batteries All the necessary protection and operating features for the load and batteries are provided An optional DC input is also provided to enable charging of batteries and powering of the load from an external 13 8V DC power source The units are fully enclosed ready for direct wall mounting All connections are at the rear of unit providing convenient wiring and installation User access to all load and battery fusing has been provided from the front of the unit Operation Safety Refer to the installation section before operating Correct installation is the most critical factor in ensuring the safe use of the power supply If every consideration of these instructions has been satisfied the power supply will be safe to operate If the AC supply cord is damaged it must be replaced by the manufacturer its service agent or similarly qualified persons in order to avoid hazard The unit is rated to charge a single 12V up to 6 cells lead acid battery at 100Ahr Capacity Functional Diagram Fuse Panel AC DC a Gra
5. ds until such case that the fault is removed Fusing Each load circuit and the battery have been fused to provide fault protection and discrimination Refer to servicing section for maximum fuse ratings CAUTION This appliance is not intended for use by young children or infirm persons without supervision Young children should be supervised to ensure that they do not play with the appliance In order to avoid hazard when the supply cord becomes damaged the cord must only be replaced by the manufacturer or its service agent or similar technically qualified person Power supply unit should only be powered from either 240VAC mains or Auxiliary Power Auxiliary Power also includes solar power but not both Failure to do so may result in damage to power supply Page 3 of 11 Issue D ST lIll Series Power Supplies USER INSTRUCTIONS Installation Host Equipment The host equipment must ensure that access to the unit other than the front panel by the user is prevented Personnel Installation is to be carried out only by suitably qualified personnel Ventilation Provide a minimum of 80mm clearance above below and behind the unit The final enclosure must also provide adequate ventilation to the outside world or larger internal cavity to prevent the build up of hot air Failure to provide adequate ventilation will mean the unit may prematurely trip thermal shut down A minimum ventilation of 20 000mm to the outside world m
6. e m ve Power Supply 7 F x Loa AC Input Outputs Vadj m ve o oi ve Battery Manual 0 8A Output Battery Trickle a2 Isolation On off Input Figure Functional Block Diagram Page 1 of 11 Doc 023942 ST Ill Series Power Supplies USER INSTRUCTIONS AC DC Power Supply This provides an isolated 13 65Vdc output for powering of the load and float charging of the battery Battery current is sensed and monitored by the power supply to ensure that the maximum charging current is not exceeded Battery Features The power supply provides full battery management as per the following The power supply is a four stage battery charger with Boost VBoost 14 05V Float VFloat 13 65V Store VStore 13 25V and Trickle charge modes to ensure long battery life Battery Charging current is limited to a maximum of 10A ST20 II and 15A ST35 II This provides optimum life for the batteries To charge at the maximum battery charge current above ensure the load current plus battery current is equal or less than the maximum output current The charging current will be reduced in situations where the difference between the rated output current and the load current the available charging current is less than the maximum charging current Also note that the battery current sense is provided in the Batt ve battery output For this feature to work the load ve and battery Batt ve should not be cross connect
7. ed Appliances should not be connected to both the Batt ve and ve terminals of the power supply Appliances should be connected to the ve and ve load terminals Low Voltage Disconnection of the batteries is provided to prevent deep discharge of the battery Automatic reconnection occurs when battery voltage recovers Battery Current Drain is less than 2mA Trickle Charge to the battery is always present When the battery voltage is below the LVD Low voltage disconnect re connect voltage lt 10V and the mains power or auxiliary power is available the battery will be charging at 0 8A When the battery voltage is sufficient gt 10 5V for first power up 11 5V and 11 7V for subsequent reconnection with and without mains respectively the LVD will connect the battery and allow float charging at 10A 15A ST20 II ST35 ID The Trickle Charge feature is provided to allow very flat batteries to be charged at a rate which will extend their life Remote Battery Isolate Switch The ST III series power supplies allow for connection to a remotely positioned switch that provides a manual disconnection of the battery from the loads and the main charger When the switch contacts are closed the battery will be isolated from the loads NOTE When the battery is isolated from the loads using the battery isolate switch it will NOT charge at the 10 15 A rate even if the mains is connected to the power supply In this condition i
8. ge is still functional when powered through Aux In VE terminal of power supply Suitable fuse protection must be provided for this input A fuse rating not exceeding 20 Amps for ST20 I and 30 Amps for ST35 II must be used Solar power should be connected directly across the battery terminals with a voltage regulator in series A solar panel voltage regulator with maximum output voltage not exceeding 14 8 volts must be used at all times Failure to use a voltage regulator may result in power supply damage Generator 12 volt outputs should not be connected across battery terminal whilst battery is connected to power supply or connected to the Aux In VE terminal of power supply Serious power supply damage or internal explosion may occur Ifa flat 12 volt battery has to be charged using the generators 12 volt output it should first be disconnected from the power supply Once battery has being charged it can then be reconnected to power supply Power supply unit should only be powered from either 240VAC mains or Auxiliary Power Auxiliary Power also includes solar power but not both Failure to do so may result in damage to power supply Protection the power supply provides automatic protection for overload including short circuit over voltage over temperature and reverse connected battery In such instances the Fault indicator will illuminate and the power supply will shut down It will attempt to automatically restart every 5 secon
9. nce with Radios and TV s located in close proximity 0 15MHz S5MHZ 30MHz EN55022 Class A Limit u AM Band m o 30dB Margin Nx ST20 II1 35 III Conducted Emissions However care still needs to be taken with the routing of cables and placement of the unit with respect to appliances Small emissions can still cause interference If interference is present then locate cables from the power supply away from appliance so far as possible and also locate the power supply away as far as practical Page 11 of 11 Issue D
10. out Battery storage mode timer has timed out 24 hour timer Periodic boost mode set 15 minute timer Battery Charging Voltage Over Time LVD Close 11 5V VFloat 13 65V VStore 13 25V 24Hrs 24Hrs Trickle Charge 0 8Amps Time Periodic VBoost 14 05V 15Mins Page 10 of 11 Periodic Vboost Issue D ST Ill Series Power Supplies USER INSTRUCTIONS Electromagnetic compatibility EMC Electromagnetic compatibility EMC is defined as the ability of a device equipment or system to function satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic disturbance to anything in that environment Switch mode power supplies are good generators of EMI and as such care needs to taken during their designs to limit their emissions Requirements of the local regulator ACA limit the emissions to protect the frequency spectrum Limits are set down in standards such as EN55022 for radiated and conducted emissions However these limits are not satisfactory for devices in close proximity lt 3m and as such do not guarantee that the power supply will not cause interference with devices such as TV s or radios The ST20 II 35 III have been designed with equipment interoperability in mind The emissions are in the order of 10 100 times below the regulator requirements this is expressed in dB uV and greatly reduce the likelihood of causing interfere
11. propriate times throughout it s usage cycle To prevent corrosion on the battery positive plate due to continuous float charging current VFloat 13 65V the unit utilises a storage mode voltage VStore 13 25V when no activity on the battery is detected This extends the battery life During store mode the unit exits to boost mode VBoost 14 05V for 15 minutes every 24hrs to maintain charge in the battery If battery activity is detected during store mode it exits automatically into float mode For any decision making involving the loss of mains detection there is a 2 minute mains debounce period where there must be no mains signal present on the mains detect input for the no mains signal to be valid A detailed description of the operational requirements for the charging algorithm is described below Present Output Conditions Required to Operational state New Output Set Set Voltage Enter Operational State P Voltage N A Microcontroller first power Initial application of power Vfloat up to the microcontroller either from 240VAC mains input or connection of a battery to the battery input Includes Auxiliary power Vfloat No Mains Mains input detected after Float charging mode with Vfloat Input loss of mains for less than mains input voltage 1 hour detected set 24 hour timer Vboost Mains input voltage was Float charging mode with Vfloat detected for more than 15 mains input voltage minutes detected set
12. s Battery should be disconnected as per the following steps Turn power supply off and all 12 volt equipment connected to power supply Disconnect negative battery terminal connection to Batt VE power supply terminal or negative chassis ground 1 Disconnect positive battery terminal to Batt VE power supply terminal Batteries When using batteries with this product always consult with the battery manufacturer for a detailed description of the installation use and maintenance of the battery Ensure battery has been charged for several days before a major camping trip Leave the power supply on for at least 2 5 days with battery connected This product is suitable for charging 12V Sealed Lead Acid SLA batteries including Valve Regulated Lead Acid VRLA batteries both Absorbed Glass Mat AGM and Gel batteries One or two batteries with max 100Ah capacity each can be charged Charging current is limited to 10A ST20 II and 15SA ST35 II Page 6 of 11 Issue D ST Ill Series Power Supplies USER INSTRUCTIONS CAUTION Ensure that there is good ventilation from the battery area Ensure that cable connections to batteries have the correct polarity and are protected against accidental short circuit Ensure that the shrouding supplied with the battery is fitted to the terminals Provide visual notification that batteries are being used in area of use Before servicing a battery disconnect the power supply Bat
13. t will ONLY charge at the Trickle charge rate Front Panel Indicators The ST III series power supplies have 3 indicators visible on the front fascia Mains GREEN is illuminated when mains power is present Battery ORANGE is illuminated when the battery is connected to the loads Fault RED is illuminated when there is a fault with the power supply Battery fuse Blown Battery connected reverse polarity Shut down condition UV and OTY Main PCB micro controller malfunction Notes 1 Flashing Is ON 1s OFF 2 Solid ON Page 2 of 11 Issue D ST Ill Series Power Supplies USER INSTRUCTIONS 3 Flashing Is ON 1s OFF with no battery connected the power supply may be in hiccup mode which will cause the indication to flash with random duty cycle and frequency 4 Fault Led Solid On All other leds OFF irrespective of actual mains or LVD status Auxiliary Power Input The power supply terminal Aux In VE provides an alternative option for powering of the load and float charging of the batteries when mains voltages are not present This input is to be powered by a suitable 12V system i e CAR The voltage of the auxiliary power source should not exceed 14 8 volts When operating via the external input current and voltage control for the battery must be provided from the external source The ST20 II 35 II does not provide battery current limit or voltage control when operating in this configuration Trickle Char
14. teries are electrically alive at all times and must be treated with extreme caution They can supply high short circuit currents even if they appear damaged Take care that dropping or touching of metal objects onto the battery cell does not cause short circuits Remove any personal metal adornment such as a chain watch or ring which could cause short circuits and personal injury Do not charge non rechargeable batteries Failure to do so may result in the battery catching on fire or possible explosion Servicing Personnel This product contains hazardous voltages and energy hazards which can result in death or injury Only properly qualified service personnel may service it There are no internal user serviceable parts Only the fuses located in the fuse panel located on the front panel are serviceable Isolate mains power Vext and battery before servicing Replacement of Fuses Only the DC output Load and Battery fuses may be replaced Fuse ratings Load fuses 20A max Battery Fuse 35A max Fuse types 32V Automotive Bussmann ATC series or Littelfuse 257 series or equivalent Page 7 of 11 Issue D ST Ill Series Power Supplies USER INSTRUCTIONS Specification Input Voltage ST20 II amp ST35 II 230 240Vac nominal 10 50 60Hz The power supply will withstand a 5 minute 15 surge on the maximum nominal voltage Input Surge Hold up Time lt 40A cold start gt 10mS at full load current and
15. ust be provided CAUTION Do not install unit in same compartment as batteries or flammable material such as petrol Ensure that the installation meets the ventilation requirements above Mechanical and Mounting 303 5 Four by 4 5 x 9mm Mounting holes at 129 5 h x 287 w centres Fuse Panel Door a 12 34 56 78 BAT Label Recess Cut out for mounting 152 h x 272 w 156 5 Depth of unit is 125mm After mounting unit clip on the front fascia ensure that all locking clips have engaged and secure with screw located inside the fuse panel door Orientation The unit is to be installed with the front fascia in a vertical plane Failure to do this will cause premature temperature shut down Page 4 of 11 Issue D ST lll Series Power Supplies USER INSTRUCTIONS Wiring Up Mains This is pre cabled and fitted with AS NZ mains plug ready for connection to internal GPO Ensure that the connection to the mains supply is in accordance with the national wiring rules and that the earth connection is installed Load Battery and External DC Input Connections Connectors are 0 8 x 6 3mm QC tabs Use mating QC connector suitable for cable size Connector pin out is shown below
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