Samlexpower SeC-1215UL User manual

OWNER'S
MANUAL
Please read this
manual BEFORE
operating your
battery charger
Switch Mode,
Automatic, Lead
Acid Battery
Charger
MODELS:
SEC-1215UL
SEC-1230UL
SEC-2415UL

2 | SAMLEX AMERICA INC.
OWNER'S MANUAL: Battery Chargers | Index
SECTION 1
Safety Precautions ................................................................ 3
SECTION 2
Layout .......................................................................... 4
SECTION 3
Description, Features & Cooling ........................................... 7
SECTION 4
Charging Stages & Protections ............................................. 8
SECTION 5
Installation & Charger Operation ....................................... 10
SECTION 6
Troubleshooting ................................................................. 15
SECTION 7
Internal Fuse Rating & Specications .................................. 17
SECTION 8
Warranty ......................................................................... 18

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3
SECTION 1 | Safety Precautions
Hazardous conditions may result if
the charger is not installed or operat-
ed correctly. Please read the following
instructions to prevent personal injury
or damage to the charger:
Battery Related
• Toreducetheriskofbatteryexplosion,
followtheseinstructionsandthose
markedonthebattery
• Neversmokeorallowanopenspark
orameinthevicinityofthebatteryor
engine
• ChargeonlyLeadAcidtypeofbatteries
(Flooded/AbsorbedGlassMat(AGM)
/GelCell).Donotchargeothertypeof
batterieslikeNickelCadmium
(NiCad)
• Nickel-MetalHydride(Ni-MH),Dry-Cell
etc.Othertypesofbatteriesmightburst
causing personal injury
• Neverchargeafrozenbattery
• WorkinginthevicinityofLeadAcidbat-
teriesisdangerous.Batteriesgenerate
explosivegasesduringnormalopera-
tion.Takenecessarysafetyprecautions
wheninstallingthechargerneara
battery or in a battery compartment
(Followsafetyinstructionsgivenbythe
batterymanufacturer)
• Neverplacethechargerdirectlyabove
orbelowthebatterybeingcharged;
gasesoruidsfromthebatterywillcor-
rodeanddamagethecharger.Locate
thechargerasfarawayfromthebat-
teryasDCcablespermit.Donotinstall
in the same compartmentas batteries
Charger Related
• Donotoperatethechargerinaclosed-
inareaorrestrictventilationinanyway.
• Installinawellventilated,cool,
dryplace.
• Thechargermustnotbeoperatedin
adamporwetenvironment.When
mountinginaboat,makesureitisnot
subjectedtobilgewatersplash
• Donotblocktheventilationopenings
/openingsforthecoolingfan.There
should be at least 6 inches clearance all
around the unit
• Installationandwiringmustcomply
withthelocalandthenational
electricalcodes.
• Itisrecommendedthatinstallation
andwiringmaybedonebya
certied electrician
• Wronginstallationonaboatmaylead
tocorrosionoftheboat.Itisrecom-
mended that installation on the boat
must be carried out by a boat electrician
• DisconnecttheACinputpowertothe
chargerbeforeconnecting/disconnect-
ing the batteries or other DC loads or
whenworkingonthecharger
• DisconnecttheACinputpowerbefore
changingsettingoftheDIPSwitch
• Thechassisofthechargerisconnected
totheearthgroundpinofthepower
cordplug.Ensurethattheearthground
pinofACreceptaclefeedingthe
charger is connected to earth ground
• Donotuseanadapter.Ifagrounding
typeofreceptacleisnotavailable,
do not use this charger until the
proper outlet is installed by a
qualiedelectrician.
• Donotoperatethechargerifthepower
cord is damaged

4 | SAMLEX AMERICA INC.
SECTION 2 | Layout
12V - 15A
Automatic
Battery
Charger
Model
SEC-1215UL
4
3
87
6
5
- + + +
2
1
LEGEND:
1 - Ammeter
2 - Red LED for ON status
3 - AC input power cord
4 - DIP Switches S1, S2
5 - Common Negative
Output Terminal
6, 7 & 8 - Isolated Positive
Bank Terminals
Fig. 2.1: Layout - SEC-1215UL

4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
SECTION 2 | Layout
Fig. 2.2: Layout - SEC-1230UL
12V - 30A
Automatic
Battery
Charger
Model
SEC-1230UL
LEGEND:
1 - Ammeter
2 - Red LED for ON status
3 - AC input power cord
4 - DIP Switches S1, S2
5 - Common Negative
Output Terminal
6, 7 & 8 - Isolated Positive
Bank Terminals
2
1
4
387
6
5
- + + +

6 | SAMLEX AMERICA INC.
Fig. 2.3: Layout - SEC-2415UL
24V - 15A
Automatic
Battery
Charger
Model
SEC-2415UL
87
6
5
- + + +
2
1
4
3
LEGEND:
1 - Ammeter
2 - Red LED for ON status
3 - AC input power cord
4 - DIP Switches S1, S2
5 - Common Negative
Output Terminal
6, 7 & 8 - Isolated Positive
Bank Terminals
SECTION 2 | Layout

6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
SECTION 3 | Description, Features & Cooling
Description
ThesechargersareusedtochargeLead
AcidBatteries(Flooded,AGMorGelCell).
SEC-1215UL(Maximumchargingcurrent
15A)andSEC-1230UL(Maximumcharg-
ingcurrent30A)areusedtocharge12V
batteries.SEC-2415UL(Maximumcharging
current15A)isusedtocharge24Vbatter-
ies.Thesechargerscanbepoweredfrom
ACpowersourceofeither120V,
60Hz(Pre-set)or230V,50Hz(By
changing jumper position inside the
unit-Seepage10forinstructions).
Features
• Stateoftheartswitchedmodetechnol-
ogyisusedforveryhighefciency,
lightweightandquietoperation.
• UserselectableACinputvoltage-
120V,60Hz(Pre-set)or230V,50Hz
(By changing jumper position inside the
unit(Seepage10forinstructions).
• Userselectable2or3stagecharging
algorithmensuresrapidandsafecharg-
ingofalltypesofleadacidbatteries
-Flooded,AGM,GelCellorbatteries
withexternalload.(Throughexternally
accessibleDIPSwitch-seepages11for
instructions)
• Fullyautomatic"ConnectandForget"
operation
• 3banksofbatteriescanbecharged
simultaneouslywithoutuseofan
externalbatteryisolator
• MonitoringthroughONstatusLED
andAmmeter
• Temperaturecontrolledcoolingfan
(SEC-1230UL,SEC-2415UL)
• Protectionsagainstshortcircuit,over
current,reversebatteryconnectionand
overtemperature(overtemperaturefor
SEC-1230ULandSEC-2415UL)
• Canbeusedasapowersupplyoras
aDCUPS(UninterruptibleDCPower
Supply)whenusedwithabattery(DIP
Switchsetat"Batterywithload")
Cooling
SEC-1215ULiscooledbyconvectionand
doesnothaveanythermaloverload
shutdown.
SEC-1230UL and SEC-2415UL are cooled by
convectionandinaddition,haveatem-
peraturecontrolledfanforforcedaircool-
ing.Twotemperaturesensorsmountedon
thepowertransformercontroltheswitch-
ingofthefanandovertemperatureshut
down.Thefanwillbeswitchedonbythe
rsttemperaturesensorwhenthepower
transformerreaches70°C.
Hence, at lower loads, the fan may not
cut in and will be off. This is normal.
Incasethefanfailsorifthecoolingisnot
adequate,thesecondtemperaturesen-
sorwillshutdowntheunitifthepower
transformerreaches100°C.TheredLED
willswitchOFF.Theunitwillautomatically
recoveronremovalofthermaloverload
condition.

8 | SAMLEX AMERICA INC.
SECTION 4 | Charging States & Protections
Thesechargerscanbemanuallyselected
to operate in 3 stage or 2 stage modes
(Pleasesee"Selecting the Type of Battery
and Charging Stages"atpage11).The
chargingstagesaredescribedbelow:
Stage 1 - Constant Current or
Bulk Charge Stage
Whenthebatteryislow,itwilltryto
drawlargerchargingcurrent.Thecharger
sensesthecurrentdrawandlimitsthis
tothemaximumpermissiblevalue(15A
forSEC-1215UL/SEC-2415ULand30Afor
SEC-1230UL).Bulkchargingtakesplaceat
thisconstantcurrent.In this condition of
constant current, the voltage measured
at the charger or battery terminals will be
the battery's own voltage.
Theconstantcurrentinjectedintothe
battery starts restoring the battery capac-
ityandit'svoltagestartsrising.When
thisvoltageapproachesthethreshold
ofbattery"gassing",termed"Boostor
AbsorptionVoltage",thechargerauto-
maticallyswitchesovertoStage2-"Boost
orAbsorptionStage".Thevalueofthis
voltagedependsuponthetypeofbattery
beingcharged(SeeDIPSwitchSettings).
Bythistime,approximately80%ofthe
batterycapacitywillnormallyhavebeen
restored (Note:Thepercentagecapac-
ity restored till the point the battery
reachestheBoostorAbsorptionVoltageis
inverselyproportionaltothevalueofthe
bulkchargecurrent.)
Stage 2 - Constant Voltage Boost
or Absorption Stage
Asexplainedabove,whenthebattery
voltageapproachesthepointwhere
battery"gassing"canbegin,thecharger
automaticallyswitchesovertothe"Boost
orAbsorptionStage".Thechargerapplies
aconstantvoltagewhosevaluedepends
uponthetypeofbatteryselected(SeeDIP
SwitchSettings).Thiscontrolledover-
chargerestoresthebalance20%ofthe
capacityinaminimumamountoftime.As
thecapacityisfullyrestored,thecharging
currentstartsreducing.Whenthecurrent
reducesbelowthepresetthreshold,the
chargerautomaticallyswitchestothe
"FloatorMaintenanceStage".
Stage 3 - Constant Voltage , Float
or Maintenance Charging Stage
Asexplainedabove,asthechargingcur-
rentdropsbelowthepresetthreshold
(1.5to2ampsforSEC-1215UL/SEC-2415UL
and2.5Ato3AforSEC-1230UL),itsignals
thatthebatteryis100%charged.
NOTES:
1.VOLTAGEREADINGSONNOLOAD
TheoutputhasonecommonNegativeterminalandthreePositiveterminalsforcharg-
ing3banksofbatteries.EachPositiveterminalhasaninternalisolatingdiodeinseries
whichhasaforwardvoltagedropof0.8to1.1V.Onnoload(thatiswhennobattery
orotherDCloadisconnectedtoanyofthe3terminals),thevoltagereadingwill
read0.8to1.1Vhigherthanthespeciedoatvoltage.Notethatthespeciedoat
voltageisataloadof1A.Also,thevoltageontheterminalsnotconnectedtothe
load(forexample,whenonebankofbatteryisconnectedtoonePositiveterminal,
theother2Positiveterminalswillremaindisconnected)willread0.8to1.1Volthigher
thanthevoltageoftheloadedterminal.
2.VOLTAGESPECIFICATIONS
Allratedvoltagesarespeciedatbatterytemperatureof80°F.

8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
SECTION 4 | Charging States & Protections
Inthis"FloatorMaintenanceCharging
Stage",thechargeroutputsaconstant
voltageof13.5Vfor12Vsystemand
27Vfor24Vsystem.Thishelpsinmain-
taining100%capacityofthebatteryand
alsocompensatesforselfdischarge.The
battery can remain connected in this stage
indenitelywithouttheriskofovercharg-
ingorexcessivelossofelectrolyte.
CAUTION!
3stagechargingisrecommendedfor
chargingstand-alone,unloadedbatteries
(there is no load connected to the battery
whenitisbeingcharged).
Ifaloadisalsoconnectedsimultaneously,a
partofthecharger'soutputcurrentwillbe
divertedtothIsload.Thus,thechargermay
remainlockedinthe"BoostorAbsorption
Mode"ifthecurrentdrawnbytheloadis
morethanthepresetvalueofthreshold
currentdeterminingchangeoverbetween
theBoostandFloatStages.This will lead to
overcharging and loss of electrolyte.
Forchargingabatterywhenaloadisalso
connectedsimultaneously,the"Boostor
AbsorptionStage"isrequiredtobedisa-
bled.Select"BatterywithLoad"usingthe
DIPswitch.Seedetailsunder"Powering
otherDCLoads"atpage14.
THE CHARGER HAS THE
FOLLOWING PROTECTIONS:
Short Circuit Shut Down
Incaseofashortcircuitontheoutputside,
thechargerwillshutdown.TheRedLED
willswitchoff.Thechargerwillautomati-
callyrecoveroncetheshortcircuitcondi-
tionisremoved.
Over load Current Limiting
Thecurrentdrawnbytheloadisauto-
maticallylimitedtoamaximumof15A
forSEC-1215UL/SEC-2415ULand30Afor
SEC-1230UL.Iftheloadtriestodrawa
highercurrentthantheselimits,theout-
putvoltageoftheunitwillstarttodrop.
If a battery is connected, the output
voltage will be clamped to the actual
battery voltage. Theunitwillautomati-
callyrecoverwhentheoverloadcondition
isremoved.
Reverse Battery Connection Cut Off
TheoutputisinternallyfusedontheDC
side.Incase,thepolarityofthebattery
connectionisreversed,thefuse(s)will
blow.TheredLEDwillswitchoff.The
fuse(s)willberequiredtobereplacedfor
theunittofunctionagain.
Thermal Overload Shutdown
SEC-1215ULiscooledbyconvectionand
doesnothaveanythermaloverload
shutdown.
SEC-1230UL and SEC-2415UL are cooled by
convectionandinaddition,haveatem-
peraturecontrolledfanforforcedaircool-
ing.Twotemperaturesensorsmountedon
thepowertransformercontroltheswitch-
ingofthefanandovertemperatureshut
down.Thefanwillbeswitchedonbythe
rsttemperaturesensorwhenthepower
transformerreaches70°C.Hence, at lower
loads, the fan may not cut in and will be
off. This is normal.
Incasethefanfailsorifthecoolingisnot
adequate,thesecondtemperaturesen-
sorwillshutdowntheunitifthepower
transformerreaches100°C.TheredLED
willswitchoff.Theunitwillautomatically
recoveronremovalofthermaloverload
condition.
CAUTION:
Keep the charger in a well ventilated,
cool and open area. Do not block the vent
holes on the sides or the discharge open-
ings of the cooling fan.

10 | SAMLEX AMERICA INC.
SECTION 5 | Installation & Charger Operation
INSTALLATION
Location, Mounting & Safety
Thechargerisrequiredtobeinstalledin
asafe,wellventilatedanddrylocation.
Pleaseseethedetailsgivenunder"Impor-
tantSafetyInstructions"onpage3.
Withthehelpof4screws,mountthe
chargeronaverticalbulkheadwiththe
outputterminalsidefacingdown.
Output connectors
Aterminalblockwithtubular,screwdown
typeofterminalsisusedforoutputcon-
nection.Thediameterofthetubularholes
isasfollows:
SEC-1215UL  0.14inches
SEC-2415UL/SEC-1230UL 0.19inches
Wires for Battery Connection
Toavoidpolarityerrorsandpossible
damage,neverusewiresofonlyone
color.Useredinsulatedwire(s)forPosi-
tiveconnection(s)andblackforNegative
connection(s)
RecommendedDCwiresizesaregiven
below.Thelengthinfeetisthelengthof
thepairofthePositiveandNegativeDC
wiresfromthechargertothebattery/
other DC load:
Lengthof
thepairof
thePositive
&Negative
cables
SEC-1215UL
SEC-2415UL SEC-1230UL
0 to 6 ft. AWG #10 AWG #8
6 to 10 ft. AWG #8 AWG #6
10 to 20 ft. AWG #6 AWG #4
Termination of Wire Ends
Wireendsforconnectiontothecharger
shouldbeterminatedwithpintypeof
lugsprovided.
CAUTION!
For rm connection when using stranded
cable, crimp / solder "pin" style terminal
on the charger end of the DC wires used
for connecting to the battery / other DC
loads.
CHARGER OPERATION
Preparing the Charger for Operation:
Selecting AC input voltage
Thechargerispre-settooperatefrom
inputACvoltageof120VAC,60Hz.
TooperatethechargerfromACinput
voltageof230VAC,50Hz,changethe
internalsettingasfollows:
1. Removethe4screwsontheammeter
sideofthetopcover
2. Gentlyslidethetopcoveroutby2to
3inches.(CAUTION! The top cover
will be restrained from fully sliding
out by the wires connecting the am-
meter, LED and the fan)
3. Locatethejumperwirewithaquick
femaledisconnect.Inthepre-set
condition,itisconnectedtothemale
verticalpinmarked"115V".Pullthis
femaledisconnectupwardstodis-
connectfromthe"115V"position.
Connectthistothemaleverticalpin
marked"230V"
4. Replacethefusewiththefuserecom-
mendedfor230VACoperation(See
fuseratingatpage17)
5. ReplacetheACplugofthepower
cordwithasuitable3pingrounded