Mean Well PB-1000 Instruction Manual

PB-1000

Instruction Manual

PB-1000 Instruction Manual

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3
3

7

10

10

11

11

7

7

7

8

8

9

9

9

9

10

3

2

4

5

1.Notes on operation

2.Front and back panel

3.Derating cu rve

4.Func tion de scription for CN100

5.LED Indication

6.Explanation of operation logic (charging stag es)

7.Func tion de scription

8.Temperature compensation

9.Suggested battery capacity

10.Series and parallel connection of batteries

11.Failure correction notes

6.1 2 stage charging (flic k switch to "2 " stage)

3.1 Ch arging current VS tempera ture

6.2 3 stage charging (flick switch to "3" stage)

36. 8 stage charging (flick switch to "8" stage)

7.1 Input voltage

7.2 PFC

7.3 Remote control

7.4 Two battery banks

7.5 2, 3, or 8 stage charging mod e selection

7.6 Reverse po larity pro tectio n

7.7 Fan speed contr ol

7.8 Charger OK relay (RY15 )

7.9 Output OK relay (RY13 & RY14)

7.1 0 Temperatu re compensation

Index

Aug. 2013 Version 7

1

0. Produc t des cr ip ti on

1. No tes on o peration:

2.Front and back panel

PB-100 0 is MW's next generation smart charg er. It has many of the protective features

th a t consu m ers wo u ld like t o h ave in a ch a r g er i n cludi n g ba tte r y m i sco n necti o n
(wro ng voltage), reve rse polarity, bat tery disconnection or not connecte d, and battery
fai l ure analy si s. The late st hi gh effi cien c y sw itchi ng topo logy plus microc o ntro lle r
po wer m anagement ar e uti l i ze d i n its d e sig n. Th ree t yp es o f cha r gi n g cu r ves ar e
offered for lead a cid ba ttery cha rgin g, 2 stag es for quick c har ging , 3 st age s (qui ck +
flo a t), and 8 st ages for optimize d chargi n g. C harging stage sel ecti on c an b e ea sily
made by th e us er thr ou gh the selec tio n switch on the fron t pa nel.

Depending on battery brand and type (lead acid, gel, lithium iron, and lithium manganese);
th e ba t tery ma y r equ ir e s pe c ia l c ha r gi n g cu r ves a nd ad j ustmen t to th e pro te c tiv e
function s which diffe rs from the standard settings. The charging curves and protective
functions can be customized by reprogramming its firmw are. Basically, you can change
the voltage/current settings of each individ ual stage plus adjust or cancel the protectiv e
fun ctio ns. Plea se note, the fa ctor y chargi ng c urv e is for charging le ad-acid batt ery.

Plea se con tact MW rega rding other t ypes of batt ery c har g ing requiremen t s.

◎Des igne d f or c ha rg in g lead acid bat te ry.
◎Mus t be installed i n a dry and well venti lated area. It sho uld not be ex pos ed to rai n

or snow.

prevent exces sive vol tage drop. Too much voltage drop will lead to longer charging
peri od.

result ing from im pro p er o p er a tio n wi l l res u lt i n cancel l at ion of warr an t y.

◎Th e cab les betw e en c harg er and b at t ery s ho u ld be ke pt as sh ort as po s si b l e to

◎Pl ea s e make s ur e chargi n g vol ta g e and c urrent meet s ba tt er y s pec ifi c at ion.
◎Refr a i n fr om con necting new a nd old b at t e ries in s eri e s.

◎Thre e years w ar ran t y is p rov i de d un der nor m a l o per atin g condi t i o ns . Fa il ur e

◎Char g er s hou ld be i n t he OFF m od e b efo re m a kin g bat tery connec tio n or dis con nec ti on.

AC I NLET

F an
Ve ntilat ion
H ol e

Figu re 2.1 Fr on t Pa ne l

ON/OFF SWIT CH

ON

AC INP UT

OFF

2

Asse mb ly gu ideline s:

1. The charger should be turne d OF F pr ior to battery con nection. Sui tabl e wire gau ge

2. Afte r p l ug g i ng in th e AC po w er cab l e, fl i ck the ON/OFF ( 0/-) s w i tch t o th e ON(-)
positio n . The LED in dica to r on the switc h will lig h t up.

should be chos en based on ra ted charging cu rrent of the charg er unit. Double-check

batt ery polarity before making the battery conn ecti on. Positive terminal of the charger
must be co nnect ed to + o f th e bat te ry and ne gativ e te rminal to of the b attery. Also,
ma ke sure t he posi t ive and n eg ative terminal s of the ch a rger are not a cc identall y
shorted toge th er.

3. De rating c ur ve

3. 1 Cha rgin g curren t VS tempe rature

AMBIENT TEMPE RATURE ( )℃

20

40

60

80

100

-20 0 10 20 30 40 50 60 70

(HORI ZONT AL)

Figu re 2.2 Ba ck P anel

LED
Indi cator

Func tion
Conn ec t or

2/3/8 sta ge
se lectio n s w itch

{

+

+

Battery ABattery B

-

-

Stage 8/3/2

Pl ease che ck battery
po larity befor e
co nnection

WARNING :

Battery B
Positive

Battery A
Positive

Common
Neg ative

Pin No. Function

Descripti on

1,2 RY13

Re la y con ta ct rat ing (m ax.): 30V/1A. "Sh ort" w hen bank A is full.

"O pen" when b an k A is stil l charg in g.

4. Fu nction desc ri ptio n for CN100

3

Pin No. Function

Descripti on

3,4

5,6

9,10

7,8

RY14

RY15

RC-/R C+

GND/RTH

Re la y con ta ct rat ing (m ax.): 30V/1A. "Sh ort" w hen bank B is f ull .

Re lay contact ra ti ng (max .): 30V /1A. "S ho rt" w hen the uni t is wo rk ing

Turn the outpu t ON a nd OFF b y el ec tr ica l or dry contac t between

Tempe ratur e sensor which comes wit h the ch ar ger ca n be conn ected

"O pen" when b an k B is sti ll cha rging .

prope rl y. "O pen" w hen th e unit ha s faile d o r protect io n has activ ated.

pin10 (RC+) and pin9 (RC-). Open: start charging. Short: stop chargin g.

to the unit to al low temperature compe ns ation of the charging v olt age.

If the temperatu re sen sor is no t u sed, the charg e r ca n sti ll w o rk
no rma ll y.

5. LE D In dicatio n

6. Ex plan ation of o pe ration l ogic (charg in g stag es):

PB - 10 0 0 has a t ot a l of 3 ch a r gi n g modes to cho ose from , 2 stag es, 3 s ta g es , and
8 stages. 8 stages char ging diffe r from 2 stag es with the addi tion of pulse, so ft start,
analysis, re conditi on, fl oat, and maintain sta ges. 2 st ages pro vide sim ple an d quick
charging. 3 stages i s sim ilar to 2 s tages with the excep tion of not shutt ing OFF afte r
the battery is fully charged. L astly, 8 stages w ill allow charging to maximu m capacity.

User can select betwee n 2, 3 or 8 stag es d ep endin g on th eir r equirement.

6.1 2 s tage ch ar gi ng ( flick switch to " 2" stage )

PB-1000 ha s ch anne ls A & B whi ch can pe rfo rm 2 stag es c hargin g indi vidua lly.
Cha nne l A wi ll be the first to commence ch arg ing. D uri ng ini tial char ge (s tag e 1) ,
cha rger will provide max imu m cu rrent to the battery. The built-i n fan will also turn
ON . As t he bat t e ry s tar t s to g et ful l, c ha r gin g c u rre n t will gr a du a l ly dec r e as e
(sta ge 2). When charging cur rent decrease to less than 10% of max. LED indicator

wi l l t ur n Gr een t o s h ow a full ch a rge. Ch ann el A wi l l t ur n OF F w hil e c ha r gi n g
com mence a t Channel B. After the ba ttery at chan nel B is fully cha rged, PB- 1000
wil l turn OF F its output s.

St a rt

B a nk A
C onsta nt
C urrent

Ba nk B
Cons tant
Curre nt

Ba nk A
Con st a nt
Volt a ge

Ba nk B
Con sta nt
Volt age

Ba nk A
Cha rg in g
En ds

Ba nk B
Cha rg in g
En ds

Types of failu re :

1

5

2 3

4

Ba ttery disconnec ted

Ac tivation of protecti on f un ction (e.g. O TP, OV P, and Short)

Damaged bat te ry Rever se pola ri t y

Incorre ct battery vo lt ag e (e .g. PB-10 00 -1 2 connected to 24V ba tter y)

St atu s

Co lor

Re d

Orang e

Green

Stea dy

Fa il

Fu ll Charg in g

Charg in g

Flashing

4

6.2 3 s tage ch ar gi ng ( flick switch to " 3" stage )

PB-1000 can only pe rfor m 3 stag es char ging to Chann el A. During initial ch arge
(sta ge 1 ), c harger will provi de ma xi m um curren t to the ba ttery. The b uilt - i n fa n
wil l also turn ON. As the batt ery star ts to g et f ull, c harg ing current will grad ually

dec rea se (s tag e 2: programmed to l a st no lo nge r th a n 24hrs). W h en charging
cur rent d ec reas e to less than 10% of max. LED in dicator will turn Green to s how
a fu ll ch a rge. The cha rger will no w main ta in a flo at ch arge vol tage (st a ge 3).

State

Constan t

Current

14.4V

PB-10 00-12

28.8V 57.6V

PB-1000-24 PB-10 00 -48

Charge Current

Con st ant Current

stage 1 stage 2

Constant Voltage

Battery Full

Start

Charge Voltage

100 %

10%

Orang e Green

Color of LE D

Fig u re 6 .1 2 s tage charging curve

Expla natio n f or 2 st ag es c har g ing curve

(0)Init ial sta ge (bat te ry a na ly sis):

(1)Stage 1 ( cons ta nt curr en t):

(2)Stage 2 ( cons ta nt volt ag e):

Chec k ba ttery vo l tage level t o see if it is wit hin th e no r mal rang e, whether or not
a ba tt er y is conn ected, or if the batte ry is a lready full and furth er ch argi ng is not

req u ired .

A constant current is provided so the ba ttery can be quickly charged to 2.4V per cell.

A co nst a nt voltag e of 2.4V per cel l is provided unt il the cha rging cur rent naturally
tap ers d own to 10% then stop char gin g .

boo st

V

V

boost

60A 34.7A 17.4A

St a rt

B a nk A
C onsta nt
C urrent

Ba nk A
Con st a nt
Volt a ge

Ban k A
Floa t
Cha rg e

5

State

V

boo st

V

fl oat

14.4V

13.8V

PB-10 00-12

28.8V

27.6V

57.6V

55.2V

PB-1000-24 PB-10 00 -48

Figure 6 .2 3 s ta g e ch arging cur ve

Constan t

Current

60A 34.7A 17.4A

100 %

10%

Expla natio n f or 3 st ag es c har g ing curve

(0)Init ial sta ge (bat te ry a na ly sis):

(1)Stage 1 ( cons ta nt curr en t):

(2)Stage 2 ( cons ta nt volt ag e):

(3)Stage 3 ( Flo at voltag e):

Chec k ba ttery vo l tage level t o see if it is wit hin th e no r mal rang e, whether or not
a ba tt er y is conn ecte d, or i f th e batter y is alre ady f ull and furth er charg i ng i s no t
req u ired .

A constant current is provided so the ba ttery can be quickly charged to 2.4V per cell.

A co nst a nt voltag e of 2.4V per cel l is provided unt il the cha rging cur rent naturally

A float voltage of 2.3V per cell is provided so that the battery can maintain full charge.

tap ers d own to 10% then mo ve on to stage 3.

Charge Current

Start

Charge Voltage

boo st

fl oat

V

V

Con st ant Cu rrent

stage 1 stage 2 stage 3

Constant Vo ltage

Battery Full

Ora ng e Green

Col or of LE D

6.3 8 s tage ch ar gi ng ( flick switch to " 8" stage )

8 stage c hargi ng provide s op timized charge to lead acid batter y. It also prolongs
bat t ery li fe a nd i ncre ase storage cap acit y. Some o f th e ma in advantages are as
bel ow:

Adva ntag e of puls e st age: Use puls e cu rren t to rev i ve aged batt ery.
Adva ntag e of reco ndit ion stag e : Allow f ull char g e of ba t tery.

◎
◎

*For ap plica tion s th at utilize the charger (PB-10 0 0) to ch arge bat t erie s an d su pply.

System power simu ltan eou sly(e .g. UPS system ), please sele ct "3 stage" cha rgin g

fo r the be st us e of t he c har g er.

6

Figure 6 .3 8 s ta ge c harg ing curv e

Cha rge
Cur ren t

stage 1 sta ge 2 sta ge 3 stag e 4 stage 5 sta ge 6 st age 7 stage 8

Cha rge
Volt age

Pu lse Soft

Start

Constan t

Cur ren t

Cons ta nt

Volt ag e

Ana lysis Float Mai ntain

Ora nge Gre en

Color of
LED

Expla natio n f or 8 st ag es c har g ing curve

(0)Initia l stage (b at tery ana l ysis ):

(1)Sta ge 1 (pulse charg ing) :

(2)Sta ge 2 (s oft start):

(3)Sta ge 3 (c on stan t cu rren t):

(4)Sta ge 4 (c on stan t vo ltag e):

Chec k ba ttery vo l tage level t o see if it is wit hin th e no r mal rang e, whether or not
a ba tt er y is conn ected, or if the batte ry is a lready full and furth er ch argi ng is not
req u ired .

Pul se charg in g is use d to rev ive ti red le ad acid battery whic h is eith er impro perl y
charged/discharg ed or allowed to self-discharge as occurs during non-use. Basically,
hel p to re stor e it s no rmal che mi c al pro pert ies.

Use l ow cha rge v ol t a ge and c ur r e nt to p repa re th e battery to a cce pt u pco mi n g

A hi gh c onstant c ur re nt is prov ide d so the batt er y can be qu ickl y ch arge d to 2 .4V
per cell.

A co nst a nt voltag e of 2.4V per cel l is provided unt il the cha rging cur rent naturally
tap ers d own to a low l evel.

bul k ch a rgi n g, so a bett er char ge c an b e applie d.

St ar t

Bank A
Pulse
Cha rge

Bank B
Pulse
Cha rge

Ban k A
Sof t
St ar t

Ban k B
Sof t
St ar t

Bank A

Bank B

Bank A

Bank B

Constant

Constant

Constant

Constant

Current

Current

Voltage

Voltage

Bank A
Floa t
Charg e

Bank B
Floa t
Charg e

A/ B main tai n cha rge cycl e

Ban k A

Ban k B

Analysis

Analysis

Ban k A

Ban k B

Mainta in

Mainta in

B ank A

B ank B

R econ ­di ti on

R econ ­di ti on

Re cond

Advantag e of float an d ma i nt ain s t age: Aft e r LE D t urns gr e e n, m ai n ten ance◎

charg e is p rov ided so t he battery is always in a full s tate. Use r will have access

to a fu ll battery whene v er i t is disco nnected from the charg e r.

7. Fu ncti on d esc ription

7 Input v o lta ge.1

PFC7.2

7.3 Re mote co ntro l

unit may be non-functional also th e act iv e PFC circuit may fai l or get damaged.

with f ull load at the ou tput . On t he othe r ha nd, if the input vo ltage is >230V o r
output is not a t fu ll loa d, the PF wi ll dro p be low 0.95.

◎Input volt age range is 90~264 Vac or 12 7~3 7 0Vdc.
◎Th e pr ov ided input volt ag e mus t fa ll wi thin the s pe cifi e d ra nge othe rwise the

◎Built- in active PFC circuit: PF>0 .95 wh en input v oltage is be twee n 90~23 0Vac

The char ge r can be t urned ON/O FF by usi ng t he " remo te con trol " f unction.

SW

9

1 0

CN1 00

RY13

RY14

RY15

GND

RC-

RY13

RY14

RY15

RTH

RC+

1

2

Betwee n RC+ (pi n1 0)
an d RC - ( pin 9)

SW o pen

SW c losed

Ch arge r

ON

OFF

(5)Sta ge 5 (ana lysi s):

Sta ge 6 (rec ondi tion boost char ge):(6)

Sta ge 7 (f loat ch ar ge):(7)

Sta ge 8 (ma i ntai n):(8)

The c ha r ge r w ill stop ch a rgi n g fo r 2 m in u t es t o determ ine bat t er y statu s. If th e

Boost vo ltage is provided to re con ditio n the battery storage capacity to it s original
sta t e.

A float vol tag e o f 2.3V per cell is prov ided for exte nded period o f time so th at the

Maint ena nce ch arge is pr ov i d ed t o compens ate f or ba tt e r y se lf- d isch arge an d
ext end batte ry life.

bat t ery can mai n tain ful l c harg e.

batt ery volt age is high er tha n 2. 1 V pe r ce l l, the battery is d eter mi ned as OK and
will move on to stage 6. If the battery voltage is lower than 2.1V per cell, the battery
fail indic atio n wi ll come ON and th e ch arge r wi ll stop charg ing .

+

+

Ba tte ry A

Battery B

-

-

Stage 8/3/2

7

7.4 Two battery banks

The cha r ger ca n be hoo k ed up to tw o ba t ter y banks ( A an d/ o r B) . Co n ne c t the

bat tery bank (s) as below. If you are conne ctin g 2 batte ry banks at t he same time,
kee p in mind tha t it m us t sha re a c om mon gr ound .

+

+

+

+

Ba ttery A

Ba ttery A

Batter y B

Batter y B

-

-

-

-

Stage 8/3/2

Stage 8/3/2

Stage 8/3/2

7.5 2, 3 , or 8 st age chargi ng mode sel ection

Th e ch arge r fe a t ures us er sel e cta b l e 2, 3, o r 8 s t ag e ch a rgi ng. T he cha r gi n g
pro f ile is selected by mo ving t he sli de sw it ch on the back pane l.

8

Swi tch

Slide right

Mid dle

Slide lef t

C har gin g mode

2 stage charging

3 stage charging

8 stage charging

Stage 8/3/2

+

+

Ba tte ry A

Ba tt ery B

-

-

Stage 8/3/2

7.6 Re vers e po larit y p r otec tion

7.7 Fa n sp eed con tr ol

7.8 Ch arge r OK rela y ( RY15)

7.9 Ou tput OK rela y (R Y13 & RY 14)

With built-in battery reverse polarity detection circuit. When the battery is connected
in rever se at the outp ut te rmi nal of the cha rge r, the out put relay circ uit will remain
ope n.

With bu ilt- i n fan sp eed c on t rol c ircuit , th e fan will auto ma tica l ly ch an g e speed
dep ending on load cond i tion .

9

1

Wor king n or mal l y

Ch ar ger

Fa ilure o r p ro tection

fu nc tio n ha s ac ti vate d

ON (s ho rt)

Be twe en pi n5 and pin 6

OFF ( ope n)

10

CN 100

RY13

RY14

RY15

GND

RC -

RY13

RY14

RY15

RTH

RC+

2

RY15

Ban k A

Ban k B

Ban k A full

Ban k B fu ll

Co lo r of LED A

Col or of L ED B

Cha rgin g

Cha rgin g

Bet ween pin1 and pin2

Bet ween pin3 and pin4

O N (s hort)

O N (s hort)

Gr ee n

Gr ee n

OF F (o pen )

OF F (o pen )

Orange

Orange

1.Ban k A OK ( RY1 3)

2.Ban k B O K (RY1 4)

9

1

10

CN 100

RY13

RY14

RY15

GND

RC-

RY13

RY14

RY15

RTH

RC+

2

RY14

RY13

9

8. Wiri ng for battery

9. Su gge st ed bat tery capa ci ty

Note: 1.Using battery capacity larger than the suggested value will not lead to damage

of the bat tery. Th e main drawback i s it may take lo nger t o fully ch arg e the
ba tter y.

2.If you're unsure about m ax allowable cha rging current of your battery, please
re fer to the ba tt er y' s tec hni c al s peci fication or consu lt its manufa cturer.

Sele ct suit able wi re gu age based o n rat ed charg ing curre nt . R ef er to the follo w in g
table for minimum wire gauge. We highly recommend using RED wire for + connection
and BLACK wire for -con nection:

AWG

14 2. 1 12

12 3. 3 22

10 5. 3 35

7 10 46

6 16 60

4 25 80

CRO SS SECTIO N(mm )

2

Max . Curre nt( A)

UL 10 1 5(60 0V 105 )℃

Mo de l

P B-10 00- 1 2 200-600AH

P B-10 00- 2 4

P B-10 00- 4 8

120-350A H

60-17 5AH

Battery capacity

10 Te mperat ure compen sation7.

Tempe rat ure se nso r which c omes with th e ch arg er can be con nec ted to the unit
to allow temper atu re co mpensation of the ch arging vo ltage. If the temperature

se ns or is no t use d, the charg er c an s till w ork no rmall y.

++

Battery ABa ttery B

--

NTC

Stage 8/3/2

10

The t empera ture
sen so r can either
be at tach ed to the
batte ry or place d
in it s surrou ndi ng
env ir onment.

11.F a ilur e correct ion no tes

If you are no t abl e to cle a r th e fa ilure co n dition, plea se c on tact Mean Well or
any of our di stributo rs for rep air service .

WARNING :

This is a class A prod uct . I n a dom esti c environ me nt

thi s product

ma y cause r a di o int erf e r en c e in wh i c h c a se t he u se r ma y be

req u ired to take adequate measu r es.

Status

Unabl e t o
cha rge
the batt ery

LED indicato r
doe s not tur n
Gre e n af ter a
lon g ch argin g
per i od

Poss ib le rea sons

ON /O FF switch in th e OFF positi on Swi tch to the ON pos ition

Re co nn ect us ing the
right po la rit y

Us e bat ter y wi th the
correc t vo ltag e

Ma ke s ur e input sou rce
is b et ween 90~264 VAC

Re pl ace with a new
batter y

Re pl ace with su itable
wi re gauge

Ba tter y re verse pol a rit y

Ba tter y wi th higher v olta ge is
con nec ted

In put AC vol tage is too low

Ba tter y ex ceeded lifesp an o r
dama ged

Ou t put ca bl es a re t o o thi n

Solu tion s

10.S erie s an d paralle l co nn ecti on o f ba tter ies

1. Ba tt er ies in series

2. Ba tt er ies in paralle l

Volt ag e ca n be d o uble d when 2 ba tter i e s are c o nn e cte d in seri es. H oweve r, th e

When 2 ba tt er ie s a r e c onn ected in pa ra ll e l , v o l ta ge rema in s t h e same an d th e
capac i ty (Ah ) doub les. F or ex am ple, 2 x 12V 100A h batteries c onnected in para llel
= 12V 200 Ah.

capacity (Ah) wi ll remain the s ame. For example, 2 x 12V 100Ah batter ies connec ted
in seri es = 24V 100Ah.

+

+

+

+

Ba ttery

Ba ttery

Ba ttery

Batte ry

-

-

-

-

11