COBHAM SAILOR 6081 User manual

SAILOR 6081
Power Supply Unit and Charger
Installation manual

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SAILOR 6081
Power Supply Unit and Charger
Installation manual
Document number: 98-130980-C
Release date: January 26, 2018

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Disclaimer
Any responsibility or liability for loss or damage in connection with the use of
this product and the accompanying documentation is disclaimed by Thrane &
Thrane A/S. The information in this manual is provided for information
purposes only, is subject to change without notice and may contain errors or
inaccuracies. Manuals issued by Thrane & Thrane A/S are periodically revised
and updated. Anyone relying on this information should acquire the most
current version e.g. from www.cobham.com/satcom, Cobham SYNC
Partner Portal, or from the distributor.Thrane & Thrane A/S is not
responsible for the content or accuracy of any translations or reproductions,
in whole or in part, of this manual from any other source. In the event of any
discrepancies, the English version shall be the governing text.
Thrane & Thrane A/S is trading as Cobham SATCOM.
Copyright
© 2018 Thrane & Thrane A/S. All rights reserved.
Manufacturer address
Thrane & Thrane A/S, Lundtoftegaardsvej 93 D, DK-2800, Kgs. Lyngby,
Denmark.
Disposal
Old electrical and electronic equipment marked with this symbol
can contain substances hazardous to human beings and the
environment. Never dispose these items together with unsorted
municipal waste (household waste). In order to protect the
environment and ensure the correct recycling of old equipment
as well as the re-utilization of individual components, use either
public collection or private collection by the local distributor of old electrical
and electronic equipment marked with this symbol.
Contact the local distributor for information about what type of return system
to use.

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Safety summary
The following general safety precautions must be observed during all
phases of operation, service and repair of this equipment. Failure to
comply with these precautions or with specific warnings elsewhere in this
manual violates safety standards of design, manufacture and intended
use of the equipment. Thrane & Thrane A/S assumes no liability for the
customer's failure to comply with these requirements.
GROUND THE EQUIPMENT
To minimise shock hazard, the equipment chassis and cabinet must be
connected to an electrical ground and the cable instructions must be
followed.
DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE
Do not operate the equipment in the presence of flammable gases or
fumes. Operation of any electrical equipment in such an environment
constitutes a definite safety hazard.
KEEP AWAY FROM LIVE CIRCUITS
Operating personnel must not remove equipment covers. Component
replacement and internal adjustment must be made by qualified
maintenance personnel. Do not service the unit with the power cable
connected. Always disconnect and discharge circuits before touching
them.
OBSERVE MARKED AREAS
Under extreme heat conditions do not touch
areas of the unit that are marked with this
symbol, as it may result in injury.
COMPASS SAFE DISTANCE
Minimum safety distance: 30 cm from the unit.
Failure to comply with the rules above will void the warranty!
Warning! Never insert or remove a power supply while its power
switch is in the On (|) position. Make sure the power
switch is Off (O) first.

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About the manual
Intended readers
This manual is an installation manual for the SAILOR 6081
Power Supply Unit and Charger. It is important that you observe
all safety requirements listed in the beginning of this manual,
and operate the SAILOR 6081 Power Supply Unit and Charger
according to the instructions and guidelines in this manual. All
installation must be done by qualified service personnel.
Manual overview
This manual has the following chapters:
•Introduction contains a description of the principle of
operation and uses and features of the power supply.
•Installation contains step-by-step guidelines how to install
the power supply as a stand-alone unit or in a combined
setup and describes the connectors.
•Service and repair contains information on support, how
to return units for repair and instructions how to exchange
the fuses.
•AppendiceswithTechnical specificationsand Upgrade
instructions.
Typography
In this manual, typography is used as indicated below:
Bold is used to emphasize words and to indicate connector
names of the unit.
Italic is used to emphasize the paragraph title in cross-
references.
Related documents
SAILOR 6080 Power Supply, Installation manual (98-129099).

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Table of contents
Chapter 1 Introduction
1.1 General description ...........................................................................1
1.2 Features .......................................................................................... 3
1.3 System configuration – examples .....................................4
Chapter 2 Installation
2.1 Unpacking................................................................................................5
2.2 Installing the SAILOR 6081 ..................................................6
Chapter 3 Service and repair
3.1 Support, repair and service........................................................27
3.2 Alarm messages ....................................................................... 29
3.3 Exchanging the fuses ............................................................ 30
3.4 Returning units for repair ...........................................................32
Chapter 4 Customizing battery settings
4.1 Battery settings.................................................................................35
4.2 Changing the battery settings .......................................... 36
Appendix A Technical specifications
A.1 SAILOR 6081 Power Supply Unit and Charger............39
A.2 SAILOR 6080 Power Supply .............................................. 41
Appendix B Upgrade
B.1 Overview................................................................................................43
B.2 Upgrading with additional SAILOR 6080 units ........ 49

Table of contents
vi
Appendix C Approvals
C.1 IEC 60945 ............................................................................................55
C.2 Wheelmark...........................................................................................55
Glossary ..................................................................................................................................57
Index ..................................................................................................................................59

vii
List of tables
Chapter 1 Introduction
Table 1: Available models and max. peak output power ...................................1
Chapter 2 Installation
Table 2: Mains AC input (on SAILOR 6080)..........................................................11
Table 3: DC output (X10)...............................................................................................12
Table 4: DC output (X11 and X12) ............................................................................12
Table 5: DC output (X13 and X14) ............................................................................13
Table 6: 15 V DC output (X15)....................................................................................13
Table 7: Battery connection (X2)...............................................................................14
Table 8: Ethernet connection (X6) ............................................................................15
Table 9: AC ALARM output (X5) .................................................................................16
Table 10: Battery alarm (X4) ...........................................................................................17
Table 11: Control data (C1, C2, C3 and C4) ............................................................18
Table 12: DC for additional units (P1, P2, P3 and P4).........................................18
Table 13: Cross link (X8, CAN bus cable)...................................................................19
Chapter 3 Service and repair
Table 14: Alarm messages................................................................................................29
Table 15: Exchange fuses .................................................................................................30
Chapter 4 Customizing battery settings
Table 16: Battery settings.................................................................................................35
App. A Technical specifications
Table 17: SAILOR 6081, Output power......................................................................39
Table 18: SAILOR 6081, General and environmental specifications...........40
Table 19: SAILOR 6080 specifications.......................................................................41
Table 20: SAILOR 6080 specifications (Continued) ............................................42

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App. B Upgrade
Table 21: Upgrade of SAILOR 6081 with one or more SAILOR 6080 ........43
App. C Approvals

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Chapter 1
1111
Introduction
Introduction 1
1.1 General description
The SAILOR 6081 Power Supply Unit and Charger provides DC power at
five DC power outlets (all separately fused) and a 15 V DC power outlet, e.g.
for CAN interface. It also charges a connected battery automatically. If the
AC power fails the SAILOR 6081 provides uninterrupted switch over to DC
power from battery to the connected equipment.
You can access control
and monitoring data via
the Ethernet interface.
The SAILOR 6081
provides dry contact
alarm output for AC
failure as well as alarm
for DC high and low
voltage on the battery.
The power supply provides up to 1480 W peak in total. The following
models are available:
Model Peak output
power
SAILOR 6081 Max. 370 W
SAILOR 6081 with 1 additional SAILOR 6080 Max. 740 W
SAILOR 6081 with 2 additional SAILOR 6080 Max. 1110 W
SAILOR 6081 with 3 additional SAILOR 6080 Max. 1480 W
Table 1: Available models and max. peak output power
Power supply
Connector panel

Chapter 1: Introduction
2 General description
Depending on the output power needed, the SAILOR 6081 Power Supply
Unit and Charger includes up to four SAILOR 6080 units and one connector
panel. The SAILOR 6081 can be upgraded on site to more output power by
adding up to three SAILOR 6080 units. The connectors for DC power are
placed at the same end of the unit for easy mounting and installation. The
connection between the SAILOR 6081 Power Supply Unit and Charger
unit(s) and the connector panel is protected by a cover. A cable relief
bracket to secure heavy cables is integrated in the wall-mount tray.
1.1.0.1 SAILOR 6080
The SAILOR 6080 Power
Supply can deliver 300 W
output power on average with
a peak of 370 W for max.
2 minutes (10% duty cycle).
The SAILOR 6081 Power
Supply Unit and Charger is AC
powered and has an on/off
switch which is lit when the
power is turned on.
1.1.1 Battery charger
In case of AC power failure or overload a battery connected to the
SAILOR 6081 Power Supply Unit and Charger delivers the required power
seamlessly. Note that output power has a higher priority than the charging
current.
To charge deeply discharged batteries (battery voltage lower than 23 V) the
SAILOR 6081 Power Supply Unit and Charger has a pre-charge mode.
Regular charging starts as soon as the battery voltage is above 23 V. The
maximum charging current and the nominal battery voltage can be
adjusted. For further details see Customizing battery settings on page 35.
Note
If the charging voltage of the battery terminal is below 8 V the
charging process will not start.

Chapter 1: Introduction
Features 3
1111
Introduction
1.2 Features
The SAILOR 6081 Power Supply Unit and Charger has the following
features:
Output voltage according to battery requirements (range: 24 — 31.2 V)
15 VDC output for SAILOR 3027 Terminal
DC connectors, 2 x 10 A, 2 x 20 A and 1 x 50 A
Up to 1480 W peak output power (max. 2 min., 10% duty cycle)
AC input (100-240 VAC operating) with fuse (6.3 A) with Power Factor
Correction
Automatic detection of input voltage range
AC alarm and battery voltage alarm
Ethernet connector for monitoring and control information
Battery charging function
Short circuit protection
Over-temperature protection (shutdown with automatic restart)
Switch over to battery power in case of AC supply failure
Link to control up to 8 SAILOR 6081 Power Supply Unit and Charger
units connected to the same battery
Upgrade on site by service personnel
IP 30 protection
Approval and certification: IEC 60945 and Wheelmark approval

Chapter 1: Introduction
4 System configuration – examples
1.3 System configuration – examples
The SAILOR 6081 Power Supply Unit and Charger is designed to be used in
installations that need a stable and powerful power supply with battery
charger. The drawing below shows a setup in which the SAILOR 6081 Power
Supply Unit and Charger generates the DC supply in a GMDSS system.
The drawing below shows an example how this power supply fits into an
installation with two segments, which is a GMDSS requirement. Each
segment has its own power supply, but often the two segments share the
battery.
SAILOR 6081
Power Supply
Unit and Charger
100V-240V AC DC out MF/HF Radio
Battery
Battery
voltage alarm
AC alarm
DC out VHF Radio
DC out Emergency light
15 V DC out Inmarsat C system
Ethernet
GMDSS application example
DC out
SAILOR 6081
Power Supply Unit and
Charger
SAILOR 6081
Power Supply Unit and
Charger
MF/HF
radio VHF radio Inmarsat C system VHF radio Inmarsat C System
Battery
+ -
+- +-
Cross
link
Segment1 (primary) Segment2 (duplicated)

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Chapter 2
2222
Installation
Installation 2
This chapter provides information about
•Unpacking
•Installing the SAILOR 6081
2.1 Unpacking
The following items are included in the delivery:
• SAILOR 6081 Power Supply Unit and Charger
• SAILOR 6081 Power Supply Unit and Charger Installation manual (this
manual)
• Installation kit for adding up to 2 SAILOR 6080 units
For SAILOR 6081 Power Supply Unit and Charger with 3 additional
SAILOR 6080 units you must order the following option:
• Installation kit, for mounting 3 additional SAILOR 6080 (Part number S-
406081-004)

Chapter 2: Installation
6 Installing the SAILOR 6081
2.2 Installing the SAILOR 6081
You can mount the power supply in a vertical or horizontal position. Vertical
mounting is recommended if more than 2 units are stacked.
2.2.1 Temperature conditions
The SAILOR 6081 must be placed in a ventilated area with free space
around all sides of the unit, except the bottom side.
Ambient temperature range is –15 °C to +55 °C.
If the SAILOR 6081 is installed in a location where the ambient temperature
may exceed 45 °C, we recommend placing the SAILOR 6081 where
unintentional contact is avoided. If the maximum ambient temperature
does not exceed 45 °C, the SAILOR 6081 can be placed in a public area.
The SAILOR 6081 Power Supply Unit and Charger can be mounted as a
single unit. If you need more power than a SAILOR 6081 Power Supply Unit
and Charger can deliver, upgrade by adding up to 3 SAILOR 6080 units. For
details see Upgrade on page 43.
2.2.2 Outline and dimensions
The following drawing shows the wall-mount tray of the SAILOR 6081
Power Supply Unit and Charger and the SAILOR 6080.
Warning! Never insert or remove a power supply while its power
switch is in the On (|) position. Make sure the power
switch is Off (O) first.

Chapter 2: Installation
Installing the SAILOR 6081 7
2222
Installation
327.5 ±0.50
248 ±0.40271 ±0.40 55.5 ±0.20
355 ±0.50
300 ±0.50
64.5 ±0.5
592.5 ±0.50
7 ±1
10 ±1
SAILOR 6080

Chapter 2: Installation
8 Installing the SAILOR 6081
2.2.3 Connectors
2.2.3.1 Connector overview — example
The following image shows a connector panel of a SAILOR 6081 with 2
additional SAILOR 6080.
DC input
from
SAILOR 6080
SAILOR
6080
control
data
DC output
15 V DC
output
Battery
Control interface
and alarm
connectors
Status
indicators
(LED)

Chapter 2: Installation
Installing the SAILOR 6081 9
2222
Installation
2.2.3.2 Connectors on the SAILOR 6081
SAILOR 6080 (+1)
SAILOR 6080 (+2)
SAILOR 6080
X2: DC
to battery
X10: DC output
(50A fuse)
X11: DC output
(20A fuse)
X12: DC output
(20A fuse)
X13: DC output
(10A fuse)
X14: DC output
(10A fuse)
X4: Relay output for
battery voltage
X8: Cross link to other
Power Supply and Charger
Fuse 10A
X6: Ethernet
DC inputControl data
AC input SAILOR 6080
Power Supply
+ - + - + - + -
GENERAL BATTERY ETHERNET X-LINK STATUS
X-LINK
POWER
X4
COMMON O.W.OK C.W.OK
S2 S1
X9
X8
RED
BLACK
WHIT E
BLUE
X6
++- -
X14 X13 X12 X11 X10 X2
BATTERY
P1P2
P3
P4
Fuse 10A
Fuse 10A
Fuse 10A
Fuse 20A
Fuse 20A
Fuse 20A
Fuse 20A
Fuse 50A
Fuse 50A
Fuse 50A
Fuse 20A
Fuse 20A
Fuse 20A
Fuse 20A
C1C2C3C4
X15
X15: 15 V DC
X9: Temperature
sensor S1 and S2
X5: Interface for legacy
battery panel and relay
output for AC alarm
SAILOR 6080 (+1)
SAILOR 6080 (+2)
SAILOR 6080 (+3)
SAILOR 6080 (+3)
W503: Jumper for Cross link termination
J500
+ - + - + - + -

Chapter 2: Installation
10 Installing the SAILOR 6081
2.2.3.3 Grounding
1. Connect chassis to ship with a cable (minimum wire cross section: 4
mm2) or equivalent. The maximum cable length is 1 m.
2. Connect the drain wire for each cable to the designated GND terminal
or bolt it to the mounting plate as shown below (2).
3. Ground the SAILOR 6081 Power Supply Unit and Charger to ship, for
example at the screw holding the mounting plate, as shown above (3).
2.2.4 Connectors and jumpers
•AC input (on SAILOR 6080)
•DC output (50 A) (X10)
•2 x DC output (20 A) (X11 and X12)
•2 x DC output (10 A) (X13 and X14)
•15 V DC output (3 A) (X15)
•Battery connector (X2)
•Battery temperature sensor S1 (X9)
•Ethernet interface for monitoring and control (X6)
•Interface for legacy battery panel and relay output for AC alarm (X5)
•Relay output for battery voltage alarm (X4)
•C1, C2, C3 and C4 for Control data
•P1, P2, P3 and P4 for DC input from SAILOR 6080
•Cross link interface (X8) when sharing a battery
•Jumper J500 for cross link interface (X-LINK POWER)
•Jumper W503 for termination of cross link
(2) (3)