Setec ST-III Series User manual

STIIISeries
POWERSUPPLY
Owner'sManual
PleasereadtheInstallationsectionofthis
manual eforeinstallingtheproduct.

Copyright©SetecPtyLtd2013
Disclaimer
SetecPtyLtdmakesnoclaimastotheaccuracyorsuita ilityoftheinformation
containedinthismanual.SetecPtyLtdacceptsnolia ilityforanylossor
damage,whichmayoccurasaresultofimproperorunsafeuseofitsproducts.
Warrantyisonlyvalidiftheunithasnot eenmodified ythecustomerandhas
not eenmisused.
2

Contents
Introduction..............................................................................................................4
SafetyPrecautions..............................................................................................4
Accessories.........................................................................................................5
Introduction.........................................................................................................5
Operation............................................................................................................5
FunctionalDiagram........................................................................................6
STIIIBasics........................................................................................................6
InstallingTheSTIIIPowerSupply...........................................................................9
WiringUp..........................................................................................................10
Servicing................................................................................................................12
Specifications.........................................................................................................13
BatteryManagement..............................................................................................14
FrequentlyAskedQuestions..................................................................................15
AndersonPlugOperation.......................................................................................16
AftersalesService.................................................................................................17
RepairsandAftersalesService.......................................................................17
WarrantyTermsandConditions........................................................................18
3

Introduction
SafetyPrecautions
PleasereadtheSafetyPrecautionscarefully eforeinstallingthepowersupply.
Besuretoo serveallprecautionswithoutfail.
Aftercompletinginstallation,conductatrialoperationtocheckforfaults.
WARNING
Failure to follow these instructions properly may result in personal
injury or loss of life.
Ensure that there is good ventilation from the battery area.
This appliance is not intended for use by young children or infirm persons without supervision.
Young children should be supervised to ensure that they do not play with the appliance.
Batteries are electrically alive at all times and must be treated with extreme caution. They can
supply high short circuit currents, even if they appear damaged.
Take care that dropping or touching of metal objects onto the battery cell does not cause short
circuits.
Remove any personal metal adornment such as a chain, watch or ring, which could cause
short circuits and personal injury.
CAUTION
Failure to observe these instructions properly may result in property
damage or personal injury, which may be serious depending on the
circumstances.
Refer to the installation section before operating. Correct installation is the most critical factor
in ensuring the safe use of the power supply. If every consideration of these instructions has
been satisfied the power supply will be safe to operate.
Ensure that cable connections to batteries have the correct polarity and are protected against
accidental short circuit.
Ensure that the shrouding supplied with the battery is fitted to the terminals.
Before servicing a battery, disconnect the power supply from the mains supply.
Do not charge non-rechargeable batteries. Failure to do so may result in the battery catching
on fire or possible explosion.
Do not allow water or other liquids to enter the installation area.
4

Accessories
Accessoriesprovidedwiththisproductare:
1. UserManual
Introduction
TheseinstructionsdetailtheinstallationandoperationrequirementsfortheST20
III&ST35IIIpowersupplies.Thesehave eendesignedforoperationinRV’s
providingaDCpowersystem,withoptional attery ackup.
Theunitsoperatefrom240Vacandprovideanisolated13.65Vdcoutputat20A
and35Arespectivelyforpoweringtheloadandchargingof atteries.Allthe
necessaryprotectionandoperatingfeaturesfortheloadand atteriesare
provided.AnoptionalDCinputisalsoprovidedtoena lechargingof atteries
andpoweringoftheloadfromanexternal+13.8VDCpowersource.
Theunitsarefullyenclosedreadyfordirectwallmounting.Allconnectionsareat
therearofunitprovidingconvenientwiringandinstallation.Useraccesstoall
loadand atteryfusinghas eenprovidedfromthefrontoftheunit.
Operation
Safety:Refertotheinstallationsection eforeoperating.Correctinstallationis
themostcriticalfactorinensuringthesafeuseofthepowersupply.Ifevery
considerationoftheseinstructionshas eensatisfiedthepowersupplywill e
safetooperate.
IftheACsupplycordisdamageditmust ereplaced ythemanufacturer,its
serviceagentorsimilarlyqualifiedpersonsinordertoavoidhazard.
Theunitisratedtochargeasingle12V(upto6cells)leadacid atteryat100Ahr
Capacity.
5

FunctionalDiagram
STIIIBasics
AC/DCPowerSupply:Thisprovidesanisolated13.65Vdcoutputforpoweringof
theloadandfloatchargingofthe attery.Batterycurrentissensedandmonitored
ythepowersupplytoensurethatthemaximumchargingcurrentisnot
exceeded.
BatteryFeatures:Thepowersupplyprovidesfull atterymanagementasperthe
following.
Thepowersupplyisafourstage atterychargerwithBoost(VBoost=14.05V),
Float(VFloat=13.65V),Store(VStore=13.25V)andTricklechargemodesto
ensurelong atterylife.
BatteryChargingcurrentislimitedtoamaximumof10A(ST20III)and15A
(ST35III).Thisprovidesoptimumlifeforthe atteries.
Tochargeatthemaximum atterychargecurrenta ove,ensuretheloadcurrent
plus atterycurrentisequalorlessthanthemaximumoutputcurrent.The
chargingcurrentwill ereducedinsituationswherethedifference etweenthe
ratedoutputcurrentandtheloadcurrent(theavaila lechargingcurrent),isless
thanthemaximumchargingcurrent.
Alsonotethatthe atterycurrentsenseisprovidedinthe“Batt+ve” attery
output.Forthisfeaturetowork,theload“+ve”and attery“Batt+ve”shouldnot
ecrossconnected.(Appliancesshouldnot econnectedto oththe“Batt+ve”
and“+ve”terminalsofthepowersupply.Appliancesshould econnectedtothe
“+ve”and“ve”loadterminals).
6
Figure1:FunctionalBlockDiagram
ACInput
8xLoad
Outputs
CaravanBattery
AC/DC
Vadj
BatteryLowvoltage
DisconnectCircuit
LoadRemote
disconnectCircuit
RemoteLoad
on/offInput
Battery–Ve
8xLoad
Returns
CarBattery
BAT– E
BAT+ E
DCIN+ E
– E
L1–L8
LOADSWITCH
BATERYFUSE
LOADFUSES
0.8A
Trickle

Low oltageDisconnection:(LVD)ofthe atteriesisprovidedtopreventdeep
dischargeofthe attery.Automaticreconnectionoccurswhen atteryvoltage
recovers.BatteryCurrentDrainislessthan2mA.
TrickleCharge:TrickleChargetothe atteryisalwayspresent.Whenthe attery
voltageis elowtheLVD(Lowvoltagedisconnect)reconnectvoltage(<10Vand
themainspowerorauxiliarypowerisavaila le,the atterywill echargingat
0.8A.Whenthe atteryvoltageissufficient(>10.5Vforfirstpowerup,11.5Vand
11.7Vforsu sequentreconnectionwithandwithoutmainsrespectively)theLVD
willconnectthe atteryandallowfloatchargingat10A/15A(ST20III/ST35III).
TheTrickleChargefeatureisprovidedtoallow“very”flat atteriesto echarged
atarate,whichwillextendtheirlife.
RemoteBatteryIsolateSwitch:TheSTIIIseriespowersuppliesallowfor
connectiontoaremotelypositionedswitchthatprovidesamanualdisconnection
ofthe atteryfromtheloadsandthemaincharger.Whentheswitchcontactsare
closed,the atterywill eisolatedfromtheloads.
NOTE:Whenthebatteryisisolatedfromtheloadsusingthebatteryisolate
switchitwillNOTchargeatthe10/15Arateevenifthemainsisconnected
tothepowersupply.InthisconditionitwillONLYchargeattheTrickle
chargerate.
FrontPanelIndicators:TheSTIIIseriespowersupplieshave3indicators
visi leonthefrontfascia.
Mains(GREEN)–isilluminatedwhenmainspowerispresent.
Battery(ORANGE)–isilluminatedwhenthe atteryisconnectedtotheloads.
Fault(RED)–isilluminatedwhenthereisafaultwiththepowersupply.
BatteryfuseBlown1
 Batteryconnectedreversepolarity2
 Shutdowncondition(UVandOT)3
 MainPCBmicrocontrollermalfunction4
Notes
1. Flashing1sON,1sOFF.
2. SolidON.
3. Flashing1sON,1sOFF,withnobatteryconnectedthe owersu ly
maybeinhiccu modewhichwillcausetheindicationtoflashwith
randomdutycycleandfrequency.
4. FaultLed=SolidOn,Allotherleds=OFF,irres ectiveofactualmainsor
LVDstatus.
AuxiliaryPowerInput:Thepowersupplyterminal“AuxIn+VE”providesan
alternativeoptionforpoweringoftheloadandfloatchargingofthe atterieswhen
mainsvoltagesarenotpresent.Thisinputisto epowered yasuita le+12V
system.(i.e.CAR).Thevoltageoftheauxiliarypowersourceshouldnotexceed
7

14.8volts.
Whenoperatingviatheexternalinput,currentandvoltagecontrolforthe attery
must eprovidedfromtheexternalsource.TheST20III/35IIIdoesnotprovide
atterycurrentlimitorvoltagecontrolwhenoperatinginthisconfiguration.Trickle
Chargeisstillfunctionalwhenpoweredthrough“AuxIn+VE”terminalofpower
supply.
Suita lefuseprotectionmust eprovidedforthisinput.Afuseratingnot
exceeding20AmpsforST20IIIand30AmpsforST35IIImust eused.
SolarPower:Solarpowershould econnecteddirectlyacrossthe attery
terminalswithavoltageregulatorinseries.Asolarpanelvoltageregulatorwith
maximumoutputvoltagenotexceeding14.8voltsmust eusedatalltimes.
Failuretouseavoltageregulatormayresultinpowersupplyor atterydamage.
Generator:12voltoutputsshouldnot econnectedacross atteryterminalwhilst
atteryisconnectedtopowersupplyorconnectedtothe“AuxIn+VE”terminalof
powersupply.Seriouspowersupplydamageorinternalexplosionmayoccur.If
aflat12volt atteryhasto echargedusingthegenerators12voltoutput,it
shouldfirst edisconnectedfromthepowersupply.Once atteryhas eing
chargeditcanthen ereconnectedtopowersupply.
Protection:Thepowersupplyprovidesautomaticprotectionforoverload
includingshortcircuit,overvoltage,overtemperatureandreverseconnected
attery.InsuchinstancestheFaultindicatorwillilluminateandthepowersupply
willshutdown.Itwillattempttoautomaticallyrestartevery5secondsuntilsuch
casethatthefaultisremoved.
Fusing:Eachloadcircuitandthe atteryhave eenfusedtoprovidefault
protectionanddiscrimination.Refertoservicingsectionformaximumfuseratings.
CAUTION:
Thisapplianceisnotintendedforuse yyoungchildrenorinfirmpersons
withoutsupervision.
Youngchildrenshould esupervisedtoensurethattheydonotplaywiththe
appliance.
Inordertoavoidhazardwhenthesupplycord ecomesdamaged,thecord
mustonly ereplaced ythemanufactureroritsserviceagentorsimilar
technicallyqualifiedperson.
8

InstallingTheSTIIIPowerSupply
HostEquipment:Thehostequipmentmustensurethataccesstotheunit(other
thanthefrontpanel) ytheuserisprevented.
Personnel:Installationisto ecarriedoutonly ysuita lyqualifiedpersonnel.
entilation:Provideaminimumof80mmclearancea ove, elowand ehindthe
unit.Thefinalenclosuremustalsoprovideadequateventilationtotheoutside
world(orlargerinternalcavity)topreventthe uildupofhotair.Failuretoprovide
adequateventilationwillmeantheunitmayprematurelytripthermalshutdown.A
minimumventilationof20,000mm2totheoutsideworldmust eprovided.
CAUTION
Donotinstallunitinsamecompartmentasbatteriesorflammable
materialsuchaspetrol.
Ensurethattheinstallationmeetstheventilationrequirementsabove.
MechanicalandMounting:
Depthofunitis125mm
Aftermountingunit,cliponthefrontfascia(ensurethatalllockingclipshave
engaged)andsecurewithscrewlocatedinsidethefusepaneldoor.
DCca lesmust esizedtocarrythemaximumfullloadcurrentandtonotexceed
thesystemvoltdroprequirements.Thefollowingca lesizesarerecommended.
Orientation:Theunitisto einstalledwiththefrontfasciainaverticalplane.
Failuretodothiswillcauseprematuretemperatureshutdown.
9
Cut-out for mounting
152 (h) x 272 (w)
Four by 4.5 x 9mm
Mounting holes at
129.5 (h) x 287 (w)
centres
156.5
303.5
1 2 3 4 5 6 7 8 BATT
Fuse Panel Door
Label Recess
x3 LEDS

WiringUp
Mains:Thisispreca ledandfittedwithAS/NZmainsplugreadyforconnection
tointernalGPO.Ensurethattheconnectiontothemainssupplyisinaccordance
withthenationalwiringrules,andthattheearthconnectionisinstalled.
Load,BatteryandExternalDCInputConnections:Connectorsare0.8x
6.3mmQCta s.UsematingQCconnectorsuita leforca lesize.Connectorpin
outisshown elow.
10
F4
F5
F6
F7
F8
FBATT
L1+
L2+
L3+
L4+
L5+
VBATT+
Fuse
Panel
+ve
terminals
+_
L-
L-
L-
L-
L-
VBATT-
V Ext+
-ve terminals
Plus Vext+ input
F Ext
+
_
To External
Voltage
To L-
CAUTION
V Ext+ must be supplied
from a Fused (F Ext),
external
voltage.
Load 4
Load 5
Load 6
Load 7
Load 8
F3 L1+ L-
F2 L1+ L-
F1
L1+
L-
Load 1
Load 2
Load 3
F1 L-
Load 1
Battery Isolate
On / off
Input

Cablingsizes:DCca lesmust esizedtocarrythemaximumfullloadcurrent
andnotexceedthesystemvoltdroprequirements.Thefollowingca lesizesare
recommended.
Whereca lespassthroughanypartofametalpanelorcover,ensurethata
ca leglandor ushisfittedtothehole.
BatteryConnectionProcedures:
Batteryshould econnectedasperthefollowingsteps.
1. Turnpowersupplyoffandall12voltequipmentconnectedtopower
supply.
2. Connectpositive atteryterminalto“Batt+VE”powersupplyterminal.
3. Connectnegative atteryterminalto“BattVE”powersupplyterminalor
negativechassisground.If atteryisconnectedtochassis,ensurea
connectionexistfromchassisto“Batt–VE”terminalofpowersupply.
BatteryDisconnectionProcedures:
Batteryshould edisconnectedasperthefollowingsteps.
1. Turnpowersupplyoffandall12voltequipmentconnectedtopower
supply.
2. Disconnectnegative atteryterminalconnectionto“Batt–VE”power
supplyterminalornegativechassisground.
3. Disconnectpositive atteryterminalto“Batt+VE”powersupplyterminal.
Batteries
Whenusing atterieswiththisproductalwaysconsultwiththe attery
manufacturerforadetaileddescriptionoftheinstallation,useandmaintenanceof
the attery.
Ensure atteryhas eenchargedforseveraldays eforeamajorcampingtrip
(Leavethepowersupplyonforatleast2–5dayswith atteryconnected).
Thisproductissuita leforcharging12VSealedLeadAcid(SLA) atteries
includingValveRegulatedLeadAcid(VRLA) atteries othA sor edGlassMat
(AGM)andGel atteries.Chargingcurrentislimitedto10A(ST20III)and
15A(ST35III).Oneortwo atterieswithmax.100Ahcapacityeachcan e
charged.
11

CAUTION:
Ensurethatthereisgoodventilationfromthe atteryarea.
Ensurethatca leconnectionsto atterieshavethecorrectpolarityandare
protectedagainstaccidentalshortcircuit.
Ensurethattheshroudingsuppliedwiththe atteryisfittedtotheterminals
Providevisualnotificationthat atteriesare eingusedinareaofuse.
Beforeservicinga attery,disconnectthepowersupply.
Batteriesareelectricallyaliveatalltimesandmust etreatedwithextreme
caution.Theycansupplyhighshortcircuitcurrents,eveniftheyappear
damaged.Takecarethatdroppingortouchingofmetalo jectsontothe attery
celldoesnotcauseshortcircuits.Removeanypersonalmetaladornmentsuch
asachain,watchorring,whichcouldcauseshortcircuitsandpersonalinjury.
Donotchargenonrechargea le atteries.Failuretodosomayresultinthe
atterycatchingonfireorpossi leexplosion.
Servicing
Personnel:Thisproductcontainshazardousvoltagesandenergyhazards,which
canresultindeathorinjury.Onlyproperlyqualifiedservicepersonnelmayservice
it.
Therearenointernaluserservicea leparts.Onlythefuseslocatedinthe“fuse
panel”locatedonthefrontpanelareservicea le.
Isolatemainspower,VExt+and attery eforeservicing.
ReplacementofFuses:OnlytheDCoutputLoadandBatteryfusesmay e
replaced.
Fuseratings:Loadfuses20Amax,BatteryFuse35Amax.
Fusetypes:32VAutomotiveBussmannATCseriesorLittelfuse257seriesor
equivalent
12

Specifications
Input Voltage: ST20-III & ST35-III: 230 – 240Vac nominal, ±10%, 50/60Hz.
The power supply will withstand a 5 minute, +15% surge on the
maximum nominal voltage
Input Surge: < 40A (cold start)
Hold-up Time: > 10mS at full load current and over nominal input voltage operating
range
Output Current: ST20-III: 20A Continuous (load + battery current)
ST35-III: 35A Continuous (load + battery current)
Factory Set Voltage 13.65V +/- 0.1V (Vfloat)
Load Regulation: < 2%
Output Ripple
Voltage:
< 150mV
Over Voltage
Protection:
< 17V
Over Current
Protection
ST20-III: 20A to 25A (load + battery current)
ST35-III: 35A to 38A (load + battery current)
Battery Current
Limit
10A ± 1A (ST20-III)
15A ± 1A (ST35-III)
Battery Connect/
Disconnect
Connect: 10.50 ± 0.2V (Input Mains not present) and first power up
Connect: 11.70 ± 0.2V (Input Mains not present and not first power up)
Connect: 11.50 ± 0.2V (Input Mains present)
Disconnect: 10.0 ± 0.2V
Battery Trickle
Charge
0.8A
Battery Drain < 2mA.
Efficiency: > 84%
Cooling Fan
Operation ST35-III
Only.
Cooling fan on temperature of Transformer: 95C + 3 degrees.
Cooling fan off temperature of Transformer: 75C + 3 degrees.
Ambient 0OC – 50OC
Weight: < 2kg
Standards Safety: AS/NZS 60335-1, AS/NZS 60335-2-29 & AS/NZS 61558
EMC CISPR 22 class A
Compliance: ERAC+ACMA (RCM)
13

BatteryManagement
Tomaintainthe atteryinagoodstateofhealth,anintelligentlycontrolled
chargingalgorithmisused.Thepurposeistoensurethatthecorrectvoltagesare
appliedtothe atteryterminalsattheappropriatetimesthroughoutit’susage
cycle.
Topreventcorrosiononthe atterypositiveplateduetocontinuousfloatcharging
current(VFloat=13.65V),theunitutilisesastoragemodevoltage(VStore=
13.25V)whennoactivityonthe atteryisdetected.Thisextendsthe atterylife.
Duringstoremode,theunitexitsto oostmode(VBoost=14.05V)for15minutes
every24hrstomaintainchargeinthe attery.If atteryactivityisdetectedduring
storemodeitexitsautomaticallyintofloatmode.
14
Figure2:BatteryChargingoverTime
24Hrs
15Mins
Periodic VBoost
(14.05V)
VStore
(13.25V)
VFloat
(13.65V)
24Hrs
Trickle Charge
(0.8Amps)
LVD Close
(11.5V)
Time

FrequentlyAskedQuestions
STIIICanGelbatteriesbeusedwiththeSTIII?
Yes.HoweverPLCAarenotrecommended.Pleasecheckrecommended attery
specificationsfromyourdealer.
STIIICanyouuseadeepcyclebatteryontheSTIII?
Yesyoucan,howevertheST35IIIisa etteroptionforthechargingcapa ilities
andwillhavealongerlifespan.
STIIIIstheSTIIIaSmartcharger?
TheSTIIIisasimple"Float"charger,theoutput( attery)voltageissetto13.65V
andcurrentlimitedto10A.TheSTIIIisa"4stagesmartcharger".
STIIICanIaddagenerator?
ThetypeofgeneratorusedwillimpactonhowtheSTIIIworks.Testshaveshown
thatgeneratorsthatprovideasquarewaveoutputhavealowerpeakvoltageand
maynotprovidethevoltagerequiredtoruntheSTIII.
STIIIWhentheAuxIN+terminalisusedfromthetowcar,isthisa
"straight"throughconnectiontothebattery?
TheAUXinprovidesanothersourcetooperatetheoutputloadsandchargethe
attery.IthasadiodetoensureonlycurrentcanentertheSTproductthrough
theAUXin.
STIIIHummingnoisewhenradioison.Isometimegetahummingnoise
whenlisteningtoAMradio.Whatisitandcananythingbedone?
TheSTIIIdoesoccasionallycauseinterference(orhumming)ontheAM andin
someinstallations.TheinterferenceoccurswhenthereisnoloadontheSTIII
duetopulseskipping,e.g.the atterynotconnectedwhenpluggedinto240V
mains.OnesuggestedwaytoreducethepulseskippingistolightlyloadtheSTIII
yturningonalight.PhysicallymovingtheradioortheSTIII(moredifficult)can
sometimeshelpreduceorstopthenoise.
15

TrailerPlugOperation
TowiretheSTIIItothecarfollowthediagramsforthedifferentplugtypes.For
moreinformationpleasecontactyourdealer.
16

AftersalesService
WARNING:Donotdisassemble,modify,orrepairtheunit.
Doingsomayresultinelectricshocksorfire.
RepairsandAftersalesService
ConsultyourSetecdealer.
17

WarrantyTermsandConditions
The enefitsprovidedtoyouunderthiswarrantyareinadditiontoanyotherrights
orremediesyoumayhave,asaconsumer,underanyotherlawwhichappliesto
SetecPtyLtdproducts.SetecPtyLtdgoodscomewithguarantiesthatcannot e
excludedundertheAustralianConsumerLaw.Youareentitledtoareplacement
orrefundformajorfailureandforcompensationforanyreasona lyforeseea le
lossordamage.Youareentitledtohavethegoodsrepairedorreplacedifthe
goodsfailto eofaccepta lequalityandthefailuredoesnotamounttoamajor
failure.
UnderthiswarrantySetecPtyLtdagreestorepairorreplace,atourcost,the
productpurchased yyouinAustraliaiftheproductdoesnotperformin
accordancewiththemanufacturer'sspecificationsduringtheperiodofthis
warranty.
TheSTIIIwarrantyisvalidforaperiodofoneyearfromtheoriginaldateof
purchase.Pleaseretainyourproofofpurchase,asthiswillneedto eprovided
shouldyouwishtoclaimunderthiswarranty.
To ea letoclaimunderthiswarrantyyoumust
(a)Ensuretheproductisinstalled yasuita lyqualifiedpersonandisinstalledin
accordancewiththisOwner'sManualandanyapplica leAustralianStandard.
( )Theproductmust eoperatedinaccordancewiththeinstructionsdetailedin
thismanual.
(c)Theproductmust emaintainedinaccordancewiththeinstructionsdetailedin
thismanual.
Whatisexcludedfromthiswarranty?Coverforanydamage,malfunctionor
failureresultingfromincorrectinstallation,accidentaldamage,misuse,a use,
tampering,unauthorisedrepairs,unauthorisedmodification yanyperson,
corrosiveenvironment,orinfestation yinsectsorverminareexcludedunderthis
warrantyandSetecPtyLtdacceptnolia ilityforthesame.
Howtomakeaclaimunderthiswarranty.
(a)ContactSetecPtyLtdon0392138400,oryourSetecdealer,too tainreturn
authorisation.
( )Packagetheproductadequatelytopreventanyfurtherdamage,andsendthe
producttolocationprovidedwhenyoureceivedyourreturnauthorisation.
(c)Pleaseincludewiththeproduct,proofofpurchase,adetaileddescriptionof
thefault,andyourcontactdetails.
SetecPtyLtdmayseekreim ursementofanycostsincurred ythemifaproduct
isfoundto eingoodworkingorder.
18

 000000Rev5A
DESIGNEDAND
MANUFACTUREDIN
AUSTRALIA