Mean Well PB-600-24, PB-600-48, PB-600-12 User guide

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PB-600

Instruction Manual

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PB-600 Instruction Manual

Index

0.Product description.................................................................................

1.Notes on operation

2.Front and back panel

3.Derating curve

3.1 Charging current VS temperature

3.2 Charging current VS input voltage

4.Function description for CN100

5.LED Indication

6.Explanation of operation logic (charging stages)

6.1 2 stage charging (flick switch to "2" stage)

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

6.3 8 stage charging (flick switch to "8" stage)

7.Function description

7.1 Input voltage

7.2 PFC

7.3 Remote control

7.4 2, 3, or 8 stage charging mode selection

7.5 Reverse polarity protection

7.6 Fan speed control

7.7 Charger OK relay (RY15)

7.8 Output OK relay (RY13)

7.9 Temperature compensation

8.Wir ing for bat ter y

9.Suggested battery capacity

10.Series and parallel connection of batteries

11.Recommend ed wire spe cification

12.Failure correction notes

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Sep. 2014 Version 11

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0.Produc t desc rip tion

PB-600 is MW's next generation smart charger. It has many of the protective features that con s u m e rs woul d l i k e t o h ave in a cha r g e r i nclud i n g b a ttery mis c o n nectio n (wrong voltage), reverse polarity, battery disconnection or not connected, and battery fa ilure analy sis. The lat est hi g h eff iciency swi tchin g topo logy pl us microcon trol l er po we r m a n a g e m e nt are utilized in its de s i g n . T hree types of cha rg i n g c u r v e s a r e off ered for lead acid ba ttery charging, 2 stages for q uick chargin g, 3 stages (quick + float ), an d 8 stag es fo r optimiz ed ch argi ng. Charg ing s tage sele ction can be easily ma de by t he us er thr ough the selec tion switch on the fro nt pa nel. Depending on battery brand and type (lead acid, gel, lithium iron, and lithium manganese); th e b a t tery may re q u i re special c h a rging curv e s a n d adjustmen t t o the protec t i v e functions which differs from the standard settings. The charging curves and protective functions can be customized by reprogramming its firmware. Basically, you can change the voltage/current settings of each individual stage plus adjust or cancel the protective functions. Please not e, the fac tory chargi ng cu rve i s for c harging lead-acid battery. Please contact MW reg ardi ng ot her types o f bat tery c har ging r equ irements.

1.Notes on operation:

◎Desig ned f or cha rgi ng lea d aci d battery. ◎Must be installed in a dry and well ventilated a rea. It should no t be exposed to rain

or snow.

◎Th e c a b l es between ch a r g er and battery sh o u l d be kept as shor t a s p ossible to

prevent excessive voltage drop. Too much voltage drop will lead to longer charging perio d.

◎Pl e a s e m ake sure char g i n g v oltage and cu r r e nt meets batt e r y s p ecificati o n . ◎Ref r a i n from conne ct i n g n ew and old batt e r i e s in series. ◎Char g e r s hould be in the O F F m o de before mak i n g b attery connec t io n or disconne ct i on . ◎Thre e y e a r s warr a n ty is pro v i d e d unde r n o r mal op e r a ting c o n d i tio n s . F ailur e

re s u l t ing from impr o p e r o peration wi l l r e s ult in cancel l a t io n of warran t y.

2.Front and back panel

Fan Ventila t io n Hole

AC INL ET ON/O FF SWIT C H

OFF

AC IN PUT

Figu re 2. 1 Fro nt Panel

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Battery Positive

Common Negative

LED Indi cat or

Power

Stage 8/3/2

2/3/ 8 sta ge sele cti on swit ch Functi on Connector

Battery

WARNING :

Please ch eck batt ery pola rit y bef ore

Figu re 2. 2 Back Panel

co nnection

Assem bly guidelin es:

1.The cha rger sho uld b e tur ned O FF prior to battery connecti on. Suitable wire gauge should be chosen bas ed on rated charging current of the charger unit. Double-check battery polarity before making the battery connection. Positive terminal of the charger mu st be co n nect ed to + of t he batt ery an d n egat ive te r mina l to of the b atte ry. Also , ma k e sure the p o sitiv e a n d negat i ve termi n als of the c harger a r e not acci d entall y short ed togeth er.

2. Af t e r p l u g gi n g in the AC p o w e r c able, flick t h e O N / O F F ( 0/-) switc h to t h e O N ( - )

posit ion. The LED in dica tor o n the switc h will l igh t up.

3.Derating curve

3.1 Charging cu rrent VS tem perature 3.2 Charging cu rrent VS inp ut voltage

100

-20 0 10 20 30 40 50 60 70

AMBIENT TEMPER ATURE ( )℃

4.Function description for CN10 0

Pin No. Function

1,2 RY13

Description

Rela y co ntact rat ing (max. ): 30V/ 1A. "Shor t" when battery is ful l.

"Open" w he n bat te ry is still c hargi ng.

(HO RIZON TAL)

90 95 100

INPUT VOLTAGE (VAC) 60Hz

115 264

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Pin No. Function

5,6

7,8

9,10

RY15

GND/RTH

RC-/ RC+

5.LED Indicati on

Co lor

Statu s

Re d

Description

Relay con tact rating (max.): 30V/1 A. "Sh ort" whe n th e un it is work in g

nor mally; “Open” when the unit is in a fa ul ty con dition

Temperature sen so r wh ich co mes wi th the charger can be co nn ecte d to the unit to allow tempera ture compensation of the chargin g voltage .

If the temper a ture se nsor is not us ed, t he char ge r can stil l wo rk norm ally.

Turn the ou tpu t ON a nd OFF by el ectrical or dr y co ntact bet we en

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

St eady

Fail

Flas hin g

Orang e

Green

Typ es of failure :

Full Ch ar gin g

Ba ttery disconn ect ed

Incorrect batte ry volta ge (e .g. PB-6 00 -12 conne ct e d to 24V battery)

Activat ion o f pro tection function (e.g. OTP, OVP, and Short)

Ch ar gin g

2 3

Da maged ba tte ry Re ver se po lar ity

6.Exp lanatio n of op eration l ogic (charging stages ):

PB-60 0 h a s a t ota l o f 3 c h a rgin g m o d es to cho o s e f rom, 2 s t a g es, 3 st a g e s, and 8 stages. 8 stages charging differ from 2 stages with the addition of pulse , soft start, analysis, r econd ition, float, and maintain s tages . 2 stage s provide simple and quick charging. 3 stages is similar to 2 stages with the exception of not shutting OFF aft er the battery is fully charged. Lastly, 8 stages will allow charging to maximum capacity. User ca n sel ect betwe en 2,3 or 8 sta ges depending o n the ir requirement.

6.1 2 sta ge ch arging (f lick s wit ch to "2" sta ge)

During initial charge (stage 1), charger will provide maximum current to the battery. The built-in fan will also turn ON. As the battery starts to get full, charging current wi ll gra dually de crease (stage 2). When c harg ing cu rrent decr ease to less than 10% of max. LED indicator will tur n Green to sh ow a full cha rge and the c har ger will turn OFF.

Sta rt

Charge Volt ag e

boo st

100%

Charge Current

Color of LED

stage 1 stage 2

Constant Cu rrent

Const ant Voltage

Orange Green

Bat te ry Full

10%

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State

Consta nt

Current

boo st

PB-600-12

PB-600-2 4 PB-600-4 8

40A 21A 10.5A

14.4V

28.8V 57.6V

Figure 6.1 2 s tag e cha rging cur ve

Expla nation fo r 2 sta ges charg ing curve

(0)In itial sta ge (b atte ry an alysis) :

Ch eck battery vol t age level t o see if i t is wit hin th e norm al ran ge, wheth e r or no t a ba tter y is conn ected, or if th e batt e ry is al ready f ull an d further cha r ging i s not requi red.

(1)Stage 1 ( constan t curr ent ):

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

(2)Stage 2 ( constan t voltage ):

A constant voltage of 2.4 V per cel l is prov ided until the charging current n aturally taper s down to 10% t hen s top ch arging.

6.2 3 sta ge ch arging (f lick s wit ch to "3" sta ge)

During initial charge (stage 1), charger will provide maximum current to the battery. The built-in fan will also turn ON. As the battery starts to get full, charging current will gradually decrease (stage 2: programmed to last no longer than 24hrs). When charging current decrease to less than 10 % of max. LED indicator will turn Green to show a full charge. The charger will now maintain a float charge voltage (stage 3).

Start

boost

flo at

Charge Voltage

Charge Current

Color of LED

State

Consta nt

Current

boost

float

stage 1 stage 2 stage 3

Constant Current

Constant Voltag e

Orange Green

PB-600-12

PB-600-2 4 PB-600-4 8

40A 21A 10.5A

14.4V

13.8V

28.8V

27.6V

Figur e 6.2 3 stage char ging cur ve

100%

10%

Battery Full

57.6V

55.2V

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Expla nation fo r 3 sta ges charg ing curve

(0)In itial sta ge (b atte ry an alysis) :

Ch eck battery vol t age level t o see if i t is wit hin th e norm al ran ge, wheth e r or no t a ba tter y is con nected, or i f the bat tery i s alre ady full and fu rthe r char ging i s not requi red.

(1)Stage 1 ( constan t curr ent ):

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

(2)Stage 2 ( constan t voltage ):

A constant voltage of 2.4 V per cel l is prov ided until the charging current n aturally taper s down to 10% t hen m ove on to sta ge 3.

(3)Stage 3 ( Floa t vol tage ):

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

*F o r a pplica t ions that u t ilize th e c harger (P B -600) to c h a rge batt e ries and s u p ply

sy ste m powe r simulta neously(e.g . UPS sy stem ), pl ease sele ct "3 st age" char ging

for the b est use of th e cha rger.

6.3 8 sta ge ch arging (f lick s wit ch to "8" sta ge)

8 stage charging provides o ptimized charge to lead acid b atter y. It also prolongs batte ry life and incr ease s torage ca pac ity. Some o f the m ain ad van tage s are a s below :

Advantag e of pul se stage: Use pulse curre nt to revive aged batt ery.◎ Advantag e of rec ondition sta ge: Allow fu ll charge of battery.◎ Ad v a ntage of fl o at and maint a i n stage: Afte r L E D turns gre e n , mainten a n ce ◎

charge is provided so the battery is always in a full state. User will hav e access to a full b attery wh ene ver it is dis connect ed from the char ger.

Charg e Voltag e

Charg e Curre nt

Color of LED

Start

Pul se So ft

stage 1 st ag e 2 stage 3 stage 4 stage 5 stage 6 st ag e 7 stage 8

Pulse Charge

Start

So ft Start

Co nst ant

Constant Constant Current Voltage

Cu rre nt

Co nst ant

Voltag e

Ora ng e Gre en

Battery Analysis

Ana lysis Flo at Mai ntain

Rec ond

Reconditi on

Float Charge

Figur e 6.3 8 stage char gin g cur ve

Maintai n

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Expla nation fo r 8 sta ges charg ing curve

(0) Initi al stage (b attery analysis) :

(1) Stage 1 ( pulse chargi ng):

Pulse cha rging is used to revive tired lead acid batter y whi ch is either impr operly charged/discharged or allowed to self-discharge as occurs during non-use. Basically, help to r est ore it s normal ch emi cal p rope rties.

(2) Stage 2 ( soft start):

Use l o w c h a r g e v o lt age and current to pr e p a r e t h e b a t tery to accept upcomin g bulk charg ing, so a bet ter charg e can be appl ied.

(3) Stage 3 ( constan t cur rent):

A high constant current is provided so the battery can be qu ick ly charged t o 2.4V per cel l.

(4) Stage 4 ( constan t vol tage ):

A constant voltage of 2.4 V per cel l is prov ided until the charging current n aturally taper s down to a low leve l.

(5) Stage 5 ( analysi s):

Th e ch a r g e r w i l l st op charging for 2 min u t e s t o d e t e r mine battery status. I f t h e battery vol t age is high er tha n 2.1V p er cel l, the b atte ry is de termined a s OK and will move on to stage 6. If the battery voltage is lower than 2.1V per cell, the battery fail in dicatio n will come ON and t he charge r will stop charging .

Stage 6 (re condition bo ost charg e):(6)

Boost voltage is provided to recondition the battery storage capacity to its original state.

Stage 7 (fl oat charg e):(7)

A float vo lta ge of 2.3V per cell is pro vide d for e xte nded peri od of ti me(about one day) so that t he batter y can maint ain f ull ch arge.

Stage 8 ( maintain):(8)

Ma i n t e n ance charg e i s p r o v ided to com p e n s a te for batter y s e lf -dischar g e a n d extend battery l ife.

7.Fun ction descri ptio n

7 Inpu t voltage.1

◎Input v oltage ra nge is 90~264Vac or 127~3 70Vd c. ◎Th e provi d ed inpu t volta ge must fa ll with i n the sp e cifie d range o t herwi s e the

unit may be non-functional also the active PFC circuit may fail or get damaged.

◎Eff i c ie n cy will get lower when inp u t v o l t a g e i s a t l o w l i n e . P le ase note, load

de ratin g will be r e quire d when in p ut volt a ge is be l ow 100Va c.

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PF C7.2

◎Built-in active PFC circuit: PF>0.95 when input volt age is between 90~230Vac

wi th ful l loa d at the o utpu t. On th e othe r hand , if the i nput v oltage is >230V or outpu t is no t at full loa d, the PF wil l dro p belo w 0.9 5.

7.3 Remote contr ol

The cha rger can be t urn ed ON/OFF b y using the " remote contr ol" funct ion.

Be tween RC + (pin10) and RC- (pin9)

SW open

SW closed

Power

Stage 8/3/2

Batt ery

Cha rge r

OFF

RY13

RY15

GND

RC-

CN100

RY13

RY15

RTH

RC+

7.4 2, 3, o r 8 sta ge charging mode sel ection

The charger f e a t u r e s user selec t a b l e 2 , 3 , o r 8 st age charg i n g . Th e c h a r g i n g profi le is selected b y movi ng th e slide swi tch on the ba ck panel.

Swit ch

Slid e ri ght

Midd le

Char ging mo de

2 stag e ch arging

3 stag e ch arging

Power

Stage 8/3/2

Slid e left

8 stag e ch arging

Stage 8/3/2

Batt ery

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7.5 Rev erse pola rit y prot ect ion

With built-in battery reverse polarity detection circuit. When the battery is connected in reverse at the output terminal of the charger, the output relay circuit will remain open.

7.6 Fan s peed control

Wi t h built-i n f a n s peed cont r o l circuit , t he fan will au t omatic a l l y change s p e e d depending on loa d condition.

7.7 Cha rger OK rel ay (RY1 5)

Ch arg er

Work n o rma lly

Fa ilure or pr ote c ti on

fu nction ac ti v ate d

Be t wee n p in 5 a nd pin6

7.8 Out put OK relay (RY13 )

Battery

Battery full

Charging

Between pin1 and pin2

ON (short ) Gree n

OFF (open) Orange

ON ( s hort)

OF F ( ope n)

Colo r of LED

CN1 00

RY13

RY15

GND

RTH

RC-

RC+

RY13

RY15

GN D

RY1 5

CN1 00

RY13

RY15

RTH

RC -

RC +

RY1 3

9 Tempe rature co mpe nsation7.

Temperature sensor which comes with the charg er can be c onnected to th e unit to allow temp erature co mpensation of the char ging voltage. If th e temperature

senso r is no t used , the c harger ca n sti ll wor k nor mall y.

Power

Stage 8/3/2

The te mp erature sens or can ei th er be att ac hed t o the batt ery or placed in its s urrou nding envi ronme nt.

NTC

Battery

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8.Wir ing for ba tter y

Se lect su itabl e wire gu age based on rat ed cha r ging cu rrent . Refe r t o the fo l lowing table for minimum wire gauge. We highly recommend using RED wire for + connection and BLA CK wire for -co nnec tio n:

AWG

CROSS SECTION(mm )

Max. Curr ent(A)

UL1015(600 V 105 )℃

14 2.1 12

12 3.3 22

10 5.3 35

7 10 46

6 16 60

4 25 80

9.Sug gested battery capaci ty

Model

Battery capacit y

PB-600-12 135-400AH

PB-600-24

PB-600-48

70-2 10AH

35-1 05AH

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

of t h e b a ttery. The m a i n d r awback is it m a y t a k e longer to ful l y c h a rge the batte ry.

2.If you're unsure about max allowable charging current of your battery, please refer t o the b attery' s technic al spe cif ication o r consult i ts manufactu rer.

10.Se rie s and pa ral lel co nne cti on of ba tte ries

1.Bat teries in seri es

Volt a g e c a n b e d o ubled when 2 b a t t e r i e s are connec t e d i n s e r i es. However, t h e capacity (Ah) will remain the same. For example, 2 x 12V 100Ah batteries connected in seri es = 24V 100Ah.

Batt eryBatter y

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2.Bat teries in para llel Wh e n 2 b at t er i e s ar e c onn e c t e d i n pa r a l l e l, v o l ta g e re m a i n s t h e s a m e an d t h e capac ity (Ah) do ubles. Fo r exa mple, 2 x 12V 1 00Ah batteri es con nected in para llel = 12V 200 Ah.

Batter y

11.Rec ommende d wir e spec ifi cation

Inst allat ion

Desk top, counter t op, chass is box (m ob ile )

Grou nded, fixed in place (not m obile )

SP-2, SPE-2, SPT-2,S V,SVE,SVT

S, SE, S O, SP-3, SPT-3, ST, STO, SJ, SJ E, SJO, SJT, SJTO

Safe ty rati ng Maxi mum len gth

10ft ( 3 meter )

Not spec ified

Note: Pleas e install i n acco rdance wi th the t able a bove. Wire gauge sho uld be n o

smaller than No. 18 AWG/3C. Socket type restricted to 15A, 125V (NEMA 5-15P) or 15A, 250V(NEMA 6-15P) w ith powe r cor d len gth rang ing f rom 1.8 meters to 10 met ers.

12.Fa ilure cor rec tion n ote s

Statu s

Possi ble reaso ns

Solut ion s

ON/OFF switch in the OF F positio n Switch to the ON position

Batte ry revers e pol arit y

Recon nec t usin g the right p olarity

Unabl e to charge the bat tery

Batte ry with hig her v olta ge is conne cted

Use batter y with the corre ct voltage

Ma ke su re input so urce is betw een 90~26 4VAC

Repla ce wi th a new batte ry

LED ind ica tor does no t tur n

Input AC v oltage is too lo w

Batte ry ex ceeded lifesp an or damag ed

Green a fter a long ch arging perio d

Outpu t cab les are too thin

Repla ce wi th sui tab le wire ga uge

If you ar e not a ble to clea r the failu re condition , plea se co ntact Mea n Well or any of ou r dis trib utors for repa ir servic e.

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N o . 2 8 , Wu q u an 3 r d R d. , W u g u Di s t ., N e w Ta ip e i C it y 2 48 , Ta i wa n