1177.D.01.0004_1 DC Converter Installation Manual Dec 2007
Contents
1. Red to do so may result in device failure Trigger Fig 6 10 Operator Connections Page 11 12V Battery Connections 1 Sor n Fig 7 12V Battery Connections Then securely crimp the male bullet connectors onto the wires adhering to recommended colour coding schedule Make sure that with each termination there are no exposed wires Securely press each bullet connector together and finish off by taping up the bullet connector junction with insulation tape 4 Make sure that there is no residual charge left in the A10 operator before plugging in the mini fit connector of the DC converter harness into the inverter as shown in Fig 6 If in doubt leave the A10 operator disconnected from the power for a minimum of 10 minutes before connecting the DC Converter 5 As shown in Fig 7 bolt the battery leads onto the DC Converter making sure that the RED lead is connected to the POS terminal and likewise the BLACK lead to the NEG terminal 6 Terminate the battery leads onto the battery again noting the correct battery polarity Page 12 Commissioning Procedure 1 Switch on 220V AC mains to system the same supply must connect to both the DC converter and A10 2 Check that the GREEN Mains2. CENTURION THE AUTOMATIC CHOICE www centsys co za Table of Contents Introduction Kit Components DC Converter Installation 6 Product Identification Connection Schematic 2 2 2 2 2 25 52 2 5 2 252 252 25 2 252 8 ONMECUONS e since UM Dc e DAE ede lt TO Mains Supply Connections 2 2 2 2 2 2 2 2 2 2 2 10 A10 Motor Connections 12V Battery Connections Commissioning procedure 2 2 2 2 2 2 2 2 2 2 2 2 2 18 Status Indiecallolr uu oae SE de qe de de sic hk dE 4s D NOLES anode ae X de Rak Ai un res ax E Meo ee Ne TS ek Isto des DANGER BATTERIES WILL GIVE OFF HYDROGEN GAS PHEVEHT POSSIBLE EXPLOSION CAUSED BY IGNITION FROM THE CONTROLLER KEEP DC CONVERTER ENCLOSURE AND BATTERY ENCLOSURE SEPARATE IN ADDITION ENSURE THAT THE BATTERY ENCLOSURE IS PROPERLY VENTED ADANGER THE 310V BC SUPPLY IS HAZARDOUS AND POTENTIALLY LETHAL THE A10 CON VERTER MODULE SHOULD BE INSTALLED AND MAINTAINED BY A QUALIFIED INSTALLER ONLY i IMPORTANT TO SERVICE THE DC CONVERTER PLEASE DISCONNECT THE EXTERNAL BATTERY FROM THE CONVERTER AND ISOLATE THE MAINS SUPPLY AT THE DISTRIBUTION BOARD HB THERE BE A RESIDUAL CHARGE ASSO
3. Page 13 Status Indication ee l l l l 220V Mains Status i Green LED l I Me EAC l Over voltage gt 260 check mains supply UPPER THRESHOLD Mains at nominal voltage Mains brownout condition level 1 Mains brownout condition level 2 MIDDLE THRESHOLD Mains brownout condition level3 LOWER THRESHOLD Table B Green LED Mains Indication 1 l Temperature Status LED 1 1 1 1 1 1 IE Thermal overload UPPER THRESHOLD wu LI 1 vl T 7 Reaching max temperature threshold Temperature rising level 3 Temperature rising level 2 MIDDLE THRESHOLD Temperature rising level 1 1 Temperature below S minimum indication yg 1 Table C Red LED Temperature Indication LOWER THRESHOLD Page 14 Notes Page 15 CENTURION Centurion Systems Pty Ltd Head Office Tel 27 0 11 699 2400 Fax 27 0 11 704 3412 or 0 11 462 6669 Omit 0 when dialing from outside South Africa 148 Epsom Avenue North Riding P O Box 506 Cramerview 2060 South Africa Sharecall 0860 CENTURION Sharecall number applicable when dialed from within South Africa only or visit www centsys co za for details of your nearest agent For technical support contact South African Branches and Regional Distributors Johanne
4. must be connected to the same mains supply as the A10 operator In addition to supplying power to the battery charger the mains supply is required for the DC converter to sense a mains fail condition on the A10 3 Terminate both ends of the 7 core cable that links the DC Converter to the A10 operator as shown in Fig 6 e On the DC Converter side the individual wires terminate directly into the screw terminals provided On the A10 operator side start by trimming the length of each wire so that they correspond with the wire lengths of the DC harness provided for a compact joint Page 10 UU mm II oooo DC DC Converter Nh i Operas HIER e 29 TOA10 MOTOR TO A10 MOTOR 70000000007 Orange or Yellow A10 Trigger GLAND PROTECTION ARMOURED CABLE CABLEO7ARM Bullet connectors and harness supplied with kit Refer to Fig __ ARMOURED CABLE CABLE07ARM Ensure the colours on 310V the harness match the colours on cable HV Ground where possible Failure 12V
5. CIATED WITH THE CAPACITANCE ON THE 410 OPERATOR TO ENSURE SAFETY WAIT FOR THE RESIDUAL CHARGE ON THE A10 OPERATOR TO DECAY TO SAFE LEVELS Page 2 Introduction The DC Converter allows the A10 gate operator to function with a 12V battery in the absence of AC mains The DC Converter steps up the 12V battery supply to 310V DC The inverter drive on the A10 operator then switches the high voltage DC supply to run the three phase induction motor Features ON DEMAND BATTERY BACKUP The DC Converter differs from a standard Uninterruptible Power Supply UPS in that it supplies the power required by the A10 Operator as and when the A10 requires it A standard UPS would supply the power required by the A10 Operator the instant the power fails What if the A10 is not operating The energy stored in the UPS battery is being wasted unnecessarily The DC Converter will not supply the power required by the A10 the instant the power fails Instead it waits until the A10 is activated and then supplies the power Thereby making the DC Converter significantly more energy efficient than a standard UPS BATTERY PROTECTION CIRCUITRY The Converter has built in circuitry that prevents the Converter from damaging the battery when the battery drops into a battery low condition The battery may be irreparably damaged if the A10 and Converter flatten the battery completely For this reason the Converter completely disconnects the battery from any current consu
6. Presence LED on the DC converter lights up to indicate mains present Check that the YELLOW Battery Indication LED flashes intermittently note status indication diagram see Table A below to determine approximate charge in battery 4 Testunit by failing mains and operate A10 Check that the A10 operates normally 5 Note that the ON to OFF time of the YELLOW Battery Indication LED changes to indicate battery capacity dropping due to A10 usage 6 With extended usage note that the RED Temperature Status LED starts to flash as per status indication see Table C on page 14 to indicate unit starting to warm up 7 Restore mains and ensure that the GREEN Mains Presence LED comes on 8 Test that A10 continues to operate off normal mains supply Status Indication Status Indication LED s The DC Converter status is indicated using three LED s The LED s indicate Battery Voltage Yellow LED Mains Voltage Green LED and DC Converter temperature Red LED Each TABLE shows how for the different statuses the respective LED indicates 5 Battery Status Yellow l ix I Battery overcharged 14 2V check charger no load should be 13 8V UPPER THRESHOLD fully charged Battery almost full Battery half charged Q O I ul oc T He ul E a a Battery almost flat Battery flat Battery low lt 10 5V system shutdown Table A Yellow LED Battery Voltage Indication
7. and compensate for Brown Out power failures too Under certain Brown Out conditions the A10 operator will continue to operate The concern is the A10 is operating outside of the voltage and particularly current specifications This could result in irrepara ble damage to the A10 operator The Converter addresses this concern supplementing the Mains supply and compensating for any voltage irregularities Page 3 POWER SAVING MODE The Converter implements various power saving techniques to extend the life of the battery when the Converter is in an idle state These power saving strategies come into play when Mains fails while Mains is present there is no need to implement these strategies since the battery is being charged Reducing the current consumed by the Converter when the system is in an idle state extends the time that battery backup is available This is critical to the user A battery backup unit is of little value to the user if the battery is flat before the user even operates the gate under power failure conditions AUTONOMOUS OPERATION The Converter is designed to be resilient to fault conditions If the Converter senses a fault it shuts down and resumes normal operation after a specified period of time This allows for completely autonomous operation of the Converter There is no need for the user to reset the Converter once the fault is cleared A10 OVERLOAD PROTECTION The Converter monitors the output voltage that it su
8. ming circuitry when the battery voltage drops below the battery low threshold BATTERY LOW SHUTDOWN The DC Converter constantly monitors the condition of the battery If the battery voltage falls below a minimum operating voltage the Converter discontinues operation The shutdown is intelligent in the event that the A10 is active when the battery low condition is detected The DC Converter will attempt to wait for the A10 to complete either its opening or closing cycle before shutting down If the A10 is still active 45 seconds after the Converter detected the battery low condition the Converter will shutdown irrespective of where the A10 is in its cycle THERMAL SHUTDOWN The DC Converter constantly monitors the operating temperature If the operating temperature exceeds a high temperature threshold the Converter discontinues operation As in the battery low shutdown the thermal shutdown is intelligent The DC Converter will attempt to wait for the A10 to complete either its opening or closing cycle before shutting down If the A10 is still active 45 seconds after the Converter detected the high temperature condition the Converter will shutdown irrespective of where the A10 is in its cycle The Converter will wait for the temperature to cool to acceptably low operating conditions before resuming operation BROWN OUT POWER FAILURE DETECTION The Converter monitors the Mains voltage for more than just power failures It is able to sense
9. nd 10 Schematic Diagram Page 8 A10 Inverter Electronics Rectification amp DC Coupling A v Transfomer Isolation i Transfomer Isolation 36 Opto Isoltation amp Drive dus High Voltage AI0 3 Phase Switching Induction Electronics Motor Peripheral E m 4 Electronic Components lt Remotes etc Voltage Logic amp Control Regulation A10 Logic Controller Page 9 Connections 2 E 0001000006 E e B a3 8 8 8 noo 0038 sli oro 00 5 oJ Lt E A loo a B 2222 pee o CUUUUUUUUCUU IMPORTANT FROM 220V MAINS SUPPLY SINGLE PHASE NOTE Isolator to be supplied by installer Fig 5 DC Converter Power Connections 1 Make sure that the mains supply to the system is isolated before proceeding with any connections 2 Connect the mains supply to the surge protection module of the DC converter unit as shown in Fig 5 A The DC converter
10. pplies to the A10 Operator If the A10 Operator attempts to draw too much current from the Converter the Converter shuts the supply down This prevents the Converter and the A10 from operating out of specification Normal Converter operation resumes after a period of 2 minutes The integrity of the circuitry monitoring the Converter output voltage is also checked in this manner This prevents the Converter from supplying the incorrect supply voltage to the A10 in the event that the Converter fails A10 RUN FAULT PROTECTION The Converter intelligently monitors the A10 Operator Under normal conditions the A10 Operator requires the Converter to run while the gate is opening or closing However if the A10 Operator fails then it is possible that a request could be made by the A10 for the Converter to run continuously for a period longer than 2 minutes Under these failure conditions the Converter immediately throttles the duty cycle If the fault is persistent the Converter will shut down completely If the fault clears itself at any stage the Converter will immediately resume normal operation This prevents a faulty A10 Operator from running the Converter continuously and flattening the battery unnecessarily Page 4 Kit Components DC Converter incl 2 5A charger ex battery DC CON10V2 Battery LM 12V 40A H CP5 Enclosure for 40A H battery CP6 Order separately Order separately Fig 1 Kit Components Page 5 DC Conve
11. rter Installation IVE OFF HYDROGEN GAS USED BY IGNITION FROM THE CONTROLLER AND BATTERY ENCLOSURE SEPARATE IN ERY ENCLOSURE IS PROPERLY VENTED DC Converter Enclosure Battery Enclosure Mains Isolator To mains supply in building A10 Sliding gate Operator 220V AC mains cable 3 LNE 1 5mm via mains isolator switch order code EISOL20AE1 12V Battery cable supplied with the DC Converter kit 7 Core armoured cable requiried to connect the DC converter to the A10 sliding gate operator order code CABLEO7ARM metre Fig 2 DC Converter Installation Page 6 Product Identification CONVERTER CONTROLLER apes E m M emn b x E LI i rte Wy Ay i i du 70 d a 132420358 CABLE SUPPLIED 10mm BATTERY 2A FOR ARMOURED CABLE 7 Core LEADS 1m CHARGER MAINS SURGE PROTECTION Fig 3 Product Identification Page 7 Connection Schematic Figure 4 is a schematic diagram for the DC Converter and the A10 It shows the different inputs and outputs of the DC Converter and how the outputs interface with the A10 Inverter and Logic Controller Single Phase 220V AC Mains Transfomer Baier Isolation Logic amp Control Transfomer zA Bi Isolation 15V DC o Se 10 Activation 12V DC DC Converter Fig 4 DC Converter a
12. sburg Central West 011 699 2400 Johannesburg East Rand aces eg te be eae eee ead 011 397 6401 PET EET 031 701 9583 Nes DEUM SA quio od Bat Aol vus ue n do E EE E 013 752 8074 5 rael os tok R5 eb he Rec e 012 349 1745 TOW redo ke datu hae od tabo ADR 021 552 9425 us iex gonad tae AX Gd del as 041 581 6994 5 ESS e e cet caine Bae CDAD TA CCS Bae RA dos s init SR 043 743 4923 amp EP 051 448 1714 Mori SS 053 832 3231 VELECAIGING uidet eu RIA ae cart OE ORO r Saura tie E 016 422 5667 Other Countries Please refer to our website www centsys co za Product Code Latest Revision 14 12 2007 Document Ref 1177 D 01 0004 1 O 2007 Centurion Systems Pty Ltd Master address page 0000 D 01 0004 5
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