KEPCO TBC 12-50M User manual

IMPORTANT NOTES:
1) This manual is valid for the following Model and associated serial numbers:
MODEL SERIAL NO. REV. NO.
2) A Change Page may be included at the end of the manual. All applicable changes and
revision number changes are documented with reference to the equipment serial num-
bers. Before using this Instruction Manual, check your equipment serial number to identify
your model. If in doubt, contact your nearest Kepco Representative, or the Kepco Docu-
mentation Office in New York, [phone], requesting the correct revision for your par-
ticular model and serial number.
3) The contents of this manual are protected by copyright. Reproduction of any part can be
made only with the specific written permission of Kepco, Inc.
Data subject to change without notice.
KEPCO®
THE POWER SUPPLIER™
MODEL
OPERATOR’S MANUAL
KEPCO INC.
ORDER NO. REV. NO.
KEPCO, INC. 131-38 SANFORD AVENUE FLUSHING, NY. 11355 U.S.A. TEL [phone] FAX [phone]
email: [e-mail] World Wide Web: www.kepcopower.com
An ISO 9001 Company.
©2019, KEPCO, INC
P/N 243-1400
TBC SERIES
POWER SUPPLY
BATTERY CHARGER POWER SUPPLY WITH RELAY ALARM SIGNALS
TBC SERIES
POWER SUPPLY

TBC OPR 071019 i
TABLE OF CONTENTS
SECTION PAGE
SECTION 1 - INTRODUCTION
1.1 Scope of Manual ..................................................................................................................................... 1-1
1.2 General Description................................................................................................................................. 1-1
1.3 Specifications.......................................................................................................................................... 1-1
1.4 General Features .................................................................................................................................... 1-1
1.5 Overvoltage Protections and Special Features....................................................................................... 1-4
SECTION 2 - INSTALLATION
2.1 Unpacking and Inspection....................................................................................................................... 2-1
2.2 Terminations, Controls and Indicators..................................................................................................... 2-1
2.3 AC Source Power Requirements ............................................................................................................ 2-4
2.4 Cooling.................................................................................................................................................... 2-5
2.5 Grounding................................................................................................................................................ 2-5
2.6 Circuit Breaker Locking Plate.................................................................................................................. 2-5
2.7 Rack Panel Mounting.............................................................................................................................. 2-6
SECTION 3 - OPERATING INSTRUCTIONS
3.1 General.................................................................................................................................................... 3-1
3.2 DC (Output) Grounding........................................................................................................................... 3-1
3.3 Load Wire Selection................................................................................................................................ 3-1
3.4 Load Connection, Method 1 (Local Error Sensing) ................................................................................. 3-1
3.5 Load Connection, Method 2 (Remote Error Sensing) ............................................................................. 3-2
3.6 Parallel Operation.................................................................................................................................... 3-3
1-1 TBC Series Rack Mount Battery Charger Power Supply............................................................................... ii
1-2 TBC Mechanical Outline Drawing.............................................................................................................. 1-5
2-1 TBC Series (Except TBC 24-120M and TBC 48-60M) Front Panel Controls and Indicators..................... 2-2
2-2 TBC 24-120M and TBC 48-60M Front Panel Controls and Indicators....................................................... 2-2
2-3 TBC Rear Panel......................................................................................................................................... 2-4
2-4 AC Input Power Terminal Block, TB3......................................................................................................... 2-5
2-5 Circuit Breaker Locking Plate..................................................................................................................... 2-6
2-6 Rack Mounting........................................................................................................................................... 2-7
3-1 Local Error Sensing Connections............................................................................................................... 3-2
3-2 Remote Error Sensing Connections........................................................................................................... 3-3
3-3 Suggested Wiring for up to Three TBC Units with Remote Sensing and Remote Control......................... 3-4
LIST OF FIGURES
FIGURE TITLE PAGE
LIST OF TABLES
FIGURE TITLE PAGE
1-1 Float, Equalize, and Overvoltage Protection Specifications .......................................................................1-2
1-2 Model Parameters ......................................................................................................................................1-2
1-3 General Specifications ................................................................................................................................1-3
2-1 Front Panel Controls and Indicators ...........................................................................................................2-1
2-2 TB1 Input/Output Terminal Assignments ....................................................................................................2-3
2-3 TB2 Input/Output Terminal Assignments ....................................................................................................2-3

ii TBC OPR 071019
FIGURE 1-1. TBC SERIES RACK MOUNT BATTERY CHARGER POWER SUPPLY

TBC OPR OPR 071019 1-1
SECTION 1 - INTRODUCTION
1.1 SCOPE OF MANUAL
This manual contains instructions for the installation and operation of the TBC 60-25M Battery
Charger Power Supply manufactured by Kepco, Inc., Flushing, New York, U.S.A.
1.2 GENERAL DESCRIPTION
The Kepco TBC Series of Telecommunications Battery Chargers, hereafter referred to as TBC,
consists of three major groups of Power Supplies. They are used for charging 12, 24, and 48
Volt batteries respectively, and are capable of delivering up to 120 Amps. In addition the TBC
60-25M can charge batteries ranging from 3 to 60 Volts. TBC are designed to Float-Charge
large battery arrays such as those found in telephone operating systems.
A sensing circuit is used to indicate whether current is flowing into or out of the TBC. The inter-
nal logic reports Charging Stopped when it senses that the battery is not absorbing current from
the Charger but rather is supplying current back to the TBC. This sensor is very sensitive. It can
respond to a reverse current of less than 50 milliamperes for a Charger capable of delivering up
to 120 Amperes.
1.3 SPECIFICATIONS
Table 1-2 lists specifications for Float, Equalize and Overvoltage Protection for all models. Table
1-2 indicates specifications for parameters that vary for different TBC models; Table 1-3 lists
general specifications that apply to all TBC models.
1.4 GENERAL FEATURES
• Input Circuit Breaker
• Status Indicators
— Power ON - green LED
— Float Mode - green LED
— Equalize Mode - amber LED (flashing)
— Charging Stopped - red LED
• Meters, 3-1/2 Digit LCD
— Voltmeter (separate connection also provided for remote monitoring)
— Ammeter
• 50/60 Hz Operation
• Current Balance terminal provided for parallel operation
• Equalize Charger Timer built in
— 00.0 -99.9 hours
— Start/Reset pushbuttons
• Logic (TTL) output for status monitoring
—PowerON
— Float/Equalize mode
— Charging Stopped
FIGURE 0-1.

1-2 TBC OPR OPR 071019
TABLE 1-1. FLOAT, EQUALIZE, AND OVERVOLTAGE PROTECTION SPECIFICATIONS
VN
Nominal
Voltage
VF
Float Voltage VX
Extra
Voltage
Range(1)
VE= VF+ VX
Equalize
Voltage (2)
(Factory Set)
VOVP
Overvoltage
Protection
Level (2)
Range (1) Factory
Set
12V 11.5 - 13.5V 13V 0 - 1.5V 14V 16V (3)
24V 23 - 27V 26V 0 - 3V 28V 34V (3)
48V 47 - 54V 52V 0 - 6V 56V 63V (3)
60V 0 - 60V 60V 0 - 3 63 120% ±7% of VSET (3)
(1) The upper limits of the range adjustments have a tolerance of ±5%.
(2) The Equalize voltage can not be set higher than the Overvoltage protection level.
(3) For the following models VOVP is 120% ±7% of VSET - Latch-style tracking overvoltage protection: TBC 12-50M,
TBC 12-100M, TBC 24-25M, TBC 24-50M, TBC 24-100M, TBC 48-12M, TBC 48-25M, and TBC 60-25M. Cycle power
to reset. Setting the TBC to less than 13% below the battery voltage may trigger OVP protection that requires power
cycle to reset.
TABLE 1-2. MODEL PARAMETERS
Model
Output Voltage
(Volts d-c) Output
Current
(Max)
(Amps d-c)
Input Current
(Max) Efficiency
@240V a-c Size Weight
(lbs)
[kilograms]
Nominal Range @100 -
120V a-c @200 - 240V a-c
12 VOLT MODELS
TBC 12-20M 12 11 - 15 22 9 3.7 90% A (1) 21 [9.5]
TBC 12-50M 12 11 - 15 53 9 3.7 90% A (1) 25 [11.4]
TBC 12-100M 12 11 - 15 100 18 9 90% A (1)
TBC 12-120M(3) 12 11.5 - 15 120 22 11 81% A (1) 33 [15]
24 VOLT MODELS
TBC 24-25M 24 23 - 30 26 9 3.7 92% B (2) 18.6 [11.5]
TBC 24-50M 24 23 - 30 50 18 9 92% A (1)
TBC 24-60M (4) 24 23 - 30 60 22 11 83% A (1) 33 [15]
TBC 24-100M 24 23 - 30 100 36 18 91% A (1)
TBC 24-120M (5) 24 23 - 30 120 44 22 83% A (1) 53 [24]
TBC 24-150M 24 23 - 30 150 54 27 92% A (1)
48 VOLT MODELS
TBC 48-12M 48 47 - 60 13 9 3.7 93% A (1) 25 [11.4]
TBC 48-25M 48 47 - 60 25 18 9 93% A (1)
TBC 48-30M (6) 48 47 - 60 30 22 11 84% A (1) 29.2 [13.3]
TBC 48-50M 48 47 - 60 50 36 18 84% A (1)
TBC 48-60M (7) 48 47 - 63 60 44 22 84% B (2) 53 [24]
60 VOLT MODELS
TBC 60-25M 60 2 - 63 25 19.7 14.5 90% A (1)
(1) Size A (Rack mount): 5-1/4H x 19W x 13-1/2D (inches), 133H x 483W x 343D (mm)
Size A (Wall mount): 17H x 19W x 6.6D (inches), 432H x 483W x 168D (mm)
(2) Size B (Rack mount): 8-3/4H x 19W x 15D (inches), 222H x 483W x 381D (mm)
Size B (Wall mount): 15H x 19W x 8-3/4D (inches), 381H x 483W x 222D (mm)
(3) Obsolete - TBC 12-120M replaced by TBC 12-100M.
(4) Obsolete - TBC 24-60M replaced by TBC 24-50M.
(5) Obsolete - TBC 24-120M replaced by TBC 24-100M.
(6) Obsolete - TBC 48-30M replaced by TBC 48-25M.
(7) Obsolete - TBC 48-60M replaced by TBC 48-50M.

TBC OPR OPR 071019 1-3
TABLE 1-3. GENERAL SPECIFICATIONS
SPECIFICATION RATING/DESCRIPTION CONDITION
Input Characteristics
Input Voltage Nominal: 100 - 120V a-c, 220 - 240V a-c Single Phase, Wide Range (1)
Range: 85 - 264V a-c
Frequency Nominal: 50 - 60Hz
Range: 47 - 63Hz
Leakage
Current 100 - 120V a-c Input <1.0mA a-c max. UL Method, 50-60Hz
220 - 240V a-c Input <2.0mA a-c max. VDE Method, 50-60Hz, 2 terminal connection
Initial Surge
at Turn-on 100 - 120V a-c Input 20A a-c max. First surge after being off for more than 30 seconds.
220 - 240V a-c Input 40A a-c max.
Startup Time 900mS max.
Holdup Time 30mS max.
EMI FCC Class A
Power Factor 0.99 (typ.) 100V a-c input, rated output.
Output Characteristics
Source Effect typical: 0.8% 115 ±15V a-c, 230 ±30 V a-c
Minimum - Maximum
maximum: 1.6%
Load Effect typical: 0.8% 10 to 100%
maximum: 1.5%
Temperature
Effect typical: 1.0% 0 to 50°C
maximum: 2.0%
Combined
Effect typical: 2.0% Source, Load and Temperature effects
maximum: 4.0%
Time Effect typical: 0.2% 1/2 to 8 hours
maximum: 0.5%
Environmental Characteristics
Temperature Operating: 0 to 50°C
Storage: -30 to 75°C
Humidity 95%, non condensing
Cooling Built-in d-c fans with fan stop sensor (1)
Isolation 500V d-c, 100MegOhms Output to case:
(1) TBC Models 12-20M, 12-50M, 24-25M, and 48-12M have single fan forced air cooling.

1-4 TBC OPR OPR 071019
1.5 OVERVOLTAGE PROTECTIONS AND SPECIAL FEATURES
The TBC incorporates switching power supplies with power factor correction (PFC). A Control
Board in the TBC controls and monitors critical functions of the TBC Battery Charger. The front
panel contains a main Circuit Breaker, voltage and current meters, status indicators (LED), and
an Equalize Timer control.
The Charger provides remote control connections and monitoring connections for DC output,
ON/OFF, Start/Reset, Equalize Timer, remote voltage sensing, and logic outputs for status mon-
itoring.
The Charger provides remote control connections and monitoring connections for DC out-put,
ON/OFF, Start/Reset, Equalize Timer, remote voltage sensing, and logic outputs for status mon-
itoring.
The DC output has factory preset voltage and current limit adjustments.
The TBC has an overvoltage protection circuit that senses the output at the Monitor terminals. It
compares a part of the output voltage to a reference voltage. If an overvoltage occurs, Sensing
Voltage Comparators shut off the oscillator, thereby resulting in zero output power. Similar cir-
cuits provide overcurrent and overtemperature protection, resulting in zero output power if either
condition is detected. In all cases, if the unit shuts off, the unit must be rest by either a) removing
a-c input power and the battery for about 30 seconds and then turning the unit back on again or
b) using the remote control (RC) terminals of TB2 at the rear panel to toggle the unit to OFF,
then ON for immediate reset. For overtemperature, the unit must cool sufficiently for reset to be
effective.

071019 5
FIGURE 1-2. TBC MECHANICAL OUTLINE DRAWING
1-5/(1-6 Blank)
-4/(-5 #