Thrane&Thrane Sailor 6081 Instruction Manual

INSTALLATION & USER MANUAL
SAILOR 6081 Power Supply Unit
and Charger

SAILOR 6081
Power Supply Unit and Charger
Installation and user manual
Document number: 98-130980-A
Release date: January 14, 2011

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. 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 are periodically revised and updated. Anyone
relying on this information should acquire the most current version e.g. from
http://www.thrane.com or from the distributor.
Thrane & Thrane 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.
Copyright
© 2011 Thrane & Thrane A/S. All rights reserved.
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.

iii
Safety summary 1
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 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.

iv
About the manual 2
Intended readers
This manual is an installation and user manual for the Power
Supply Unit and Charger. It is important that you observe all safety
requirements listed in the beginning of this manual, and operate
the 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.
• Appendices with Technical specifications and 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)

v
Table of Contents
Chapter 1 Introduction
General description ............................................................ 1
Features .............................................................................3
System configuration — examples .......................................4
Chapter 2 Installation
Unpacking ..........................................................................5
Installing the Power Supply Unit and Charger ....................6
Chapter 3 Service and repair
Contact for support ...........................................................25
Repair and servicing ........................................................25
Status indicators (LED) .....................................................26
Alarm messages ...............................................................27
Exchanging the fuses .......................................................28
Returning units for repair .................................................30
Chapter 4 Customizing battery settings
Battery settings ................................................................33
Changing battery settings .................................................34
App. A Technical specifications
SAILOR 6081 Power Supply Unit and Charger ...................37
SAILOR 6080 Power Supply ..............................................39

Table of Contents
vi
App. B Upgrade
Upgrade overview ............................................................. 41
Upgrading with additional SAILOR 6080 units ..................47
App. C Approvals
IEC 60945 .........................................................................55
Wheelmark .......................................................................55
Glossary .........................................................................................57
Index .........................................................................................59

1
Chapter 1
1111
Introduction
Introduction 1
General description
The Power Supply Unit and Charger provides DC power at five DC power
outlets (all separately fused) and a 15 V DC power outlet for SAILOR 3027 mini-
C Transceiver. It also charges automatically a connected battery. If the AC
power fails the power supply delivers DC power from the connected battery.
You can access control
and monitoring data via
the Ethernet interface.
There are relay outputs
for AC outage and
battery voltage alarm.
The power supply
provides up to 1480 W
in total. The following
models are available:
Depending on the output power needed, the 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
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
Power supply
Connector panel

Chapter 1: Introduction
2 General description
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
Power Supply unit(s) and the connector panel are protected against water
ingress by a protection cover. A cable relief bracket to secure heavy cables is
integrated in the wall-mount tray.
When mounted vertically the Power Supply Unit and Charger and the SAILOR
6080 Power Supply fulfill IP32 in areas with more than 42 V and IP22 in other
areas.
SAILOR 6080
The SAILOR 6080 Power Supply
can deliver 300 W output power
on average with a peak of 370 W
for a minimum of 2 minutes. It is
AC powered. The Power Supply
has an on/off switch. It is lit
when the power is turned on.
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 load deeply discharged batteries (battery voltage lower than 23 V) the
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 33.
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
Features
The Power Supply Unit and Charger has the following features:
Output voltage according to battery requirements (range: 24 — 31.2 V)
15 V DC output for SAILOR 3027 Terminal
DCconnectors,2x10A,2x20Aand1x50A
Up to 1480 W peak output power
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
No forced cooling required
Link to control up to 8 Power Supply Unit and Charger units connected to
the same battery
Upgrade on site by service personnel
IP 32 for internal high voltage areas (>42 V), IP 22 in other areas when
vertically mounted (wall) and connector panel is facing down1
Approval and certification: IEC 60945 Maritime approval, Wheelmark
1. IP 30 and IP 20 for other mounting positions.

Chapter 1: Introduction
4 System configuration — examples
System configuration — examples
The 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 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
Segment 1 (primary) Segment 2 (duplicated)

5
Chapter 2
2222
Installation
Installation 2
This chapter provides information about
•Unpacking
•Installing the Power Supply Unit and Charger
Unpacking
The following items are included in the delivery:
• SAILOR 6081 Power Supply Unit and Charger
• 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 (Part number 406081-004)

Chapter 2: Installation
6 Installing the Power Supply Unit and Charger
Installing the Power Supply Unit and Charger
You can mount the power supply in a vertical or horizontal position. When
mounted in a vertical position, with the connector panel pointing downwards,
the Power Supply fulfills IP32 in areas with more than 42 V and IP22 in other
areas.
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 41.
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.
Important
To ensure adequate cooling of the AC/DC Power Supply an
unobstructed space of minimum 5 cm must be maintained
around all sides of the unit except for the bottom side.

Chapter 2: Installation
Installing the Power Supply Unit and Charger 7
2222
Installation
Outline and dimensions
The following drawing shows the wall-mount tray of the SAILOR 6081 Power
Supply Unit and Charger and the SAILOR 6080 Power Supply.
355±0.3
300±0.3
248±0.3271±0.3
327.5±0.3
595±0.3
64.35±0.3
10±0.3
7±0.3
SAILOR 6080

Chapter 2: Installation
8 Installing the Power Supply Unit and Charger
Connectors
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 Power Supply Unit and Charger 9
2222
Installation
Connectors on the Power Supply Unit and Charger
SAILOR6080
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
+ - + - + - + -
GEN ERAL BATTERY ETH ERNET 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
P1P2P3
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: Tem perature
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 Power Supply Unit and Charger
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 Power Supply Unit and Charger to ship, for example at the
screw holding the mounting plate, as shown above (3.).
Connectors and jumpers
•AC input (on SAILOR 6080 Power Supply)
•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.)

Chapter 2: Installation
Installing the Power Supply Unit and Charger 11
2222
Installation
AC input (on SAILOR 6080 Power Supply)
The SAILOR 6080 Power Supply is AC powered. To connect the AC input do as
follows:
1. Remove the u-shaped cut-out for this input from the protective lid.
2. Connect the Mains cable to the connector marked MAINS AC.
This connector is used when adding a SAILOR 6080 Power Supply (dual row
spring loaded terminal).
Mains AC
Connector type Spring loaded terminal, dual-row connector
Wire cross section Up to 2.5 mm2
L Line. AC power cord
N Neutral. AC power cord
GND. AC power cord
Fuse 6.3 A. It is accessible from outside the housing. It is
positioned next to the on/off switch.
To remove the fuse turn the device that holds the
fuse and extract it.
AC input
To connect to additional
AC/DC Power Supply

Chapter 2: Installation
12 Installing the Power Supply Unit and Charger
DC output (50 A) (X10)
2 x DC output (20 A) (X11 and X12)
DC output (X10)
Connector type Cable shoe bolted to the board.
+ DC output plus
- DC output minus
M5 in chassis GND for drain wire (cable shield)
Fuse One 50 A fuse plate for DC output plus. You must
use the fuse with the Thrane & Thrane part
number S-33-205377-050.
DC output (X11 and X12)
Connector type Spring loaded terminal
Wire cross section Up to 6 mm2
+ DC output plus
- DC output minus
M5 in chassis GND for drain wire (cable shield)
GND for safety wire
Fuses Two 20 A fuses, one for DC output plus and one
for DC output minus.a
a. This output is rated up to 30 A, thus 30 A fuses may be used.

Chapter 2: Installation
Installing the Power Supply Unit and Charger 13
2222
Installation
2 x DC output (10 A) (X13 and X14)
15 V DC output (3 A) (X15)
DC output (X13 and X14)
Connector type Spring loaded terminal
Wire cross section Up to 2.5 mm2
+ DC output plus
- DC output minus
M5 in chassis GND for drain wire (cable shield)
GND for safety wire
Fuses Two 10 A fuses, for DC output plus and one for the
DC output minus.
15 V DC output (X15)
Connector type Spring loaded terminal
Wire cross section Up to 2.5 mm2
+ 15 V DC output plus
-15VDCoutputminus
M5 in chassis GND for drain wire (cable shield)
GND for safety wire