PowerSafe TMC 500W User manual

1800 338 979
powersafe.net.au
[e-mail]
Switchboard Thermal Management System
•Designed & tested for Australian conditions
•Multiple fans and heatsinks in each assembly
•Safe for indoor & outdoor use – IP65
•OLED monitoring screen and test function

Introduction
Congratulations on your purchase of a Powersafe TMC-500W thermal
management system. These units offer unsurpassed protection
against component over-temperature failure. The unit has been built
tough for indoor and outdoor use on a range of switchboard
enclosures.
If a switchboard generates too much thermal energy the operation of
circuit protection devices is adversely affected, creating a potential
safety risk. The TMC-500W has been proven to dissipate 500W of
heat losses at 20K (difference between internal and external
temperature, tested at 400C ambient) generated by internal
switchboard components. Many switchboard components need to be
de-rated in an environment above 400C or below 00C. Refer to
component manufacturer's specification for applicable
characteristics. Powersafe thermal management systems also
incorporate a heater for humidity and low-temperature control.
Powersafe thermal management systems have been designed
specifically with safety in mind ensuring no exposed conductive parts
and utilizing Extra-low voltage (ELV) fans. The TMC-500W has been
thoroughly tested in harsh working environments to measure
performance. The device must be installed and operated as per the
instructions in this manual.
It is the user's responsibility to ensure that the TMC-500W is used
and installed as per any Australian standards, local authority
requirements and all other standards or requirements to satisfy the
conditions of the location and functionality of the unit and its use.
Please refer to the standards that the TMC-500W has been designed
and manufactured to comply with and to ensure that it is
appropriate for its intended use.
Powersafe Thermal Management Systems are the industry leading solution for switchboard thermal
performance and safety
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Kit Contents:
•1x TMC 500W top assembly
•1x LRS-150-24 power supply unit
•1x power supply DIN mounting bracket
•1x NTL152 150W heater
•1x steel mounting plate
•12x M5 nuts
•12x M5 spring washer
•12x M5 panel washer
•1x M5 standard washer
•1x M5 ring terminal
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•The TMC-500W.1 must be installed, wired and tested by a
licenced electrician.
•Prior to installation, the assembly must be inspected for any
damage during transport. Check all connectors are firmly in
place and fasteners have not come loose.
•The enclosure to which the device is to be fitted must be in a
location that allows sufficient air flow i.e. not in a small
enclosed room.
•The assembly should be mounted horizontally on a flat, clean
surface without defects to ensure a sufficient seal. The
mounting surface may require reinforcing to prevent warping.
•To ensure optimal performance, the enclosure to which the
device is fitted should be completely sealed to minimum IP54.
•The 150W power supply unit has been selected for its technical
parameters. In case of replacement, replace only with like for
like product.
•Install power supply inside enclosure in a location away from
direct heat sources.
•Install heater in bottom corner of enclosure in a location
allowing sufficient air flow and away from combustible
materials.
Installation Precautions:
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Installation Instructions:
Step 1: Isolate, test and lock out
power from the enclosure in which
the assembly is to be installed.
Step 2: Select a suitable location in
the top of the enclosure for
installation. Ensure there is
enough clearance inside to get the
mounting bracket in. The assembly
requires 150mm recessed height
inside the enclosure and 200mm
height above for air flow. Ensure
TMC controller is away from direct
heat source.
Step 3: Use mounting plate and
measurements provided to mark
out enclosure for cutting. Take
precautions to prevent swarf/
debris from falling onto internal
components. Debur any sharp or
proud edges. Treat any raw metal
surfaces for rust prevention.
Mark out areas in RED
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Step 4: Ensure rubber seals are in place in
the bottom of heatsink plate and around the
base of orange cover and are in good
condition before inserting TMC 500W
assembly into enclosure. If internal access is
limited, the 24V supply to the TMC
controller will need to be connected prior to
insertion.
Step 5: Insert steel mounting plate from
inside enclosure into place on the 12x
grubscrews. Secure 11x grub screws with an
M5 panel washer, spring washer, and
standard nut. Do not use nyloc nuts as this
can force the grubscrews through the
aluminium heatsink plate. Torque nuts to
1Nm.
Step 6: Connect a minimum sized 4mm2
earth wire with ring terminal/ lug to the
remaining grub screw between a panel
washer and a standard M5 washer, secured
with a spring washer and standard nut. The
assembly should only be earthed at one
point.
Rubber seal Grub screwTMC Controller
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Step 8: 240V and 24V field wiring is required to be made
during installation. Use appropriately rated cable and
circuit protection to relevant standards. Use cable
protection and segregation applicable to installation.
Assembly and Power Supply Unit must be connected to
earthing system. Ensure wiring and components are
away from sources of heat.
Step 9: Conduct and record electrical tests of field wiring
prior to powering up assembly. Check earth continuity of
exposed parts of assembly <0.5 Ohms. Do not apply test
voltages above operational voltage to assembly
components. Check polarity of all field wiring to prevent
damage to components.
Step 7: Mount the Power Supply Unit on DIN rail with
the brackets provided. Ensure location is not accessible
without the use of tools and/or key and is away from
sources of heat. Mount the heater on DIN rail in the
bottom corner of enclosure and clear of wiring, circuit
protection and other heat sensitive components.
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Step 10: Test operation of assembly. Press and hold test
button while system cycles through internal and external
fan tests. Ensure all 4x fans are running to full RPM and
temperature and humidity readings are accurate. If
system fails, contact point of purchase for repair/
replacement.
Home screen
Test screens
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Technical Specifications:
Model No. TMC-500W.1
Operating Voltage 240V – AC – 50 Hz
Max. current 1A (240V)
Max. power 150W
Rated heat dissipation 25 W/K
Operating temperature
range external -25oC to + 90oC
Power Supply Unit
(PSU)
Operating range derates above 50oC, PSU has
been selected for operating temperatures up to
70oC. For high operating temperatures, alternative
PSU will be required
Mounting orientation Horizontal, flat surface
Housing material Fiberglass
Recommended Fuse >6A MCB or fuse
Recommended wiring
characteristic 1.5mm20.6/1kV
Earthing system Connect to switchboard earthing system (singular
earth cable as per instructions)
Operating altitude Below 2000m
Ingress Protection IP65
Relative humidity Max. 98%
Overall dimensions 520W x 190D x 200H
Kit weight 10kg
Storage Store in dry, clean enclosure
User/ Owners responsibility: it is required the TMC-500W is tested
regularly as required by applicable regulatory and site standards.
Regular checking of the unit by a qualified person is mandatory to the
safe operation of the unit and the individual components. Powersafe
recommends 3 monthly intervals for inspections. Inspections may be
required more frequently in more adverse operating environments or
under Australian standards or laws.
It is recommended that switchboards are fitted with a breather drain to
allow air flow into the board and for moisture to escape. Inspect
breather drain regularly to ensure debris does not build up around the
drain.
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Troubleshooting:
Problem Possible Cause Suggestions to correct
No power to OLED screen
No power to supply circuit Test and check enclosure and apply power to circuits
Circuit protection off Inspect and test wiring before applying power
Circuit polarity incorrect Inspect wiring and correct any issues
Fans do not spin up to
speed
Internal wiring issue Isolate power and inspect JTX and DTM connectors to ensure all pins are
making good contact
DIP switch settings changed Isolate power and adjust DIP switch settings to correct position
Test button flashes red Internal issue Do not use the device. Return to place of purchase for repair/ replacement.
High Temperature Alert Internal temperature too high Reduce load on switchboard components to allow internal temperature to
drop
For 4 fan operation
(2 internal and 2 external)
Both dip switches
are “ON”
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Warranty:
The manufacturer warrants that the product complies with the applicable technical
specifications and is free from any defect in workmanship and materials for a period of 5
years Pro Rata. Effective from the date of purchase of the product and any claim under
this warranty must be made within that time period. To make a claim under warranty,
ensure you have proof of purchase; return the product to the store of purchase, or
alternatively contact Powersafe Products. The consumer is responsible for costs to return
to Powersafe Products and/or the store of purchase.
Powersafe Products undertakes to repair or replace at its option the defective product or
part thereof with a comparable product or part at least equivalent as to the performances
and functionality. The replacement product or parts, which may be new or reconditioned,
are warranted for a period expiring either simultaneously with the initial warranty of the
concerned product or part thereof three (3) months after delivery of such repaired product
or part, whichever is later. Moreover, upon proof evidence, the initial warranty period may
be extended for the period you have not been able to use the product due to repair.
Warranty evaluation by the manufacturer must occur prior to repair/replacement of any
product or part. All product or parts that are replaced become the property of the
manufacturer.
THIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY:
•Non-compliance with the instructions for use, installation or maintenance of the
product, in particular regarding the power supply and climatic conditions.
•Improper maintenance of energy sources and of the general electrical installation.
•Acts of vandalism, lightning, fire, humidity, bad weather.
•Use of the product in combination with, or integration of the product into equipment
not supplied by the manufacturer, unless such combination or integration has been
expressly approved in writing by the manufacturer.
•Use of the product for a purpose other than that for which it is intended.
•Faults and deterioration caused by normal wear and tear, a shock or a fall.
•Product malfunctioning due to external causes (eg radio-electric interference
produced by other equipment, variation in voltage of the mains supply).
•Changes made to the product, including mandatory changes.
•Product from or on which the brand or serial numbers have been removed or
altered.
•Defects as a result of other goods and services being connected to the product
which disturb or affect the predicted level of service.
Powersafe Products may pay reasonable direct expenses of claiming under this warranty.
You may submit details and proof of your expenses claim to Powersafe Products for
consideration if the failure is deemed as a warranty claim.
This warranty is provided in addition to other rights or remedies you have under Australian
Law. Our goods come with guarantees, which cannot be excluded under Australian
Consumer Law. You are entitled to replacement, refund, or goods repaired if the goods are
defective and failure does not amount to a major failure.
UNLESS OTHERWISE STIPULATED BY LAW, ANY AND ALL WARANTY
PROVISION OTHER THAN THOSE MENTIONED HEREIN ARE EXPRESSLY
EXCLUDED:
You are covered by a legal warranty for this product and for all information concerning
this warranty, please call on 1800 338 979 or alternatively view the website and send
an email directly to customer service.
Warranty does not cover cost of freight to return the item to us and we do not supply
replacement boards until the warranty item has been inspected by Powersafe
Products. All warranty repairs must be carried out by Powersafe Products, or a
company appointed by Powersafe Products. Any repairs carried out prior to our
approval or without our approval will not be covered under warranty.
“Electrical safety is no accident”
Ph: 1800 338 979
www.powersafe.net.au
15/09/2022 TMC 500W User Instructions and Installation powersafe.net.au 11

[e-mail] 1800 338 979 www.powersafe.net.au
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