PowerMaster PM-SBC-2012, PM-SBC-4012F, PM-SBC-6012F, PM-SBC-1524, PM-SBC-3024F User Manual

SWITCH-MODE BATTERY CHARGER

(MICROPROCESSOR SYSTEM)

USER MANUAL

FOR ALL PATTERNS 1 AND 3 OUTPUTS

1

CONTENTS

Introduction............................................................................................................2

Technical Features.................................................................................................2

Advanced Charging Technique ............................................................................ 3

Safety Devices.........................................................................................................3

Options....................................................................................................................4

Safety Instruction...................................................................................................4

Installation..............................................................................................................5

Front Panel.............................................................................................................7

LED Indicators.......................................................................................... ............. 7

Switches Section (4 Battery Types and 1 User Define) .......................................7

Instruction of Charging Curve Selection.............................................................8

DC Power Supply................................................................................................... 9

BTS/Remote Control ...........................................................................................10

Trouble Shooting Guide......................................................................................10

Specification .............................................................. ................ ................ ........... 11

2

Introduction

Power Master Battery Charger is small and lightweight charger that offers charging
patterns which are perfectly adapted to each battery technology (liquid electrolyte, gel
electrolyte, lead calcium, etc... ). A charging pattern may be factory set to suit your
specific application.

To prolong the life of your batteries and conserve their initial

capacity, the charger is programmed

with 5 three-state charging patterns:

z BOOST Charge/FAST Charge :Restores battery capacity until 80 % in a short

space of time.

z ABSORPTION Charge/BALANCE Charge : Complements of charge until 100 %

of battery capacity

z FLOATING Charge/TOP-UP Charge : Compensates for constant battery drain,

while keeping the battery fully charged.

Power Master Battery Charger is the only charger on the market to allow the battery to

be connected and used constantly, while still offering a real BOOST (high voltage)
charge over short period. The charger switches back to top-up mode automatically.

In accordance with EC standards, the Power Master Battery charger is fitted with a PFC
(Power Factor Corrector) which limit peak current draw from the input power required
from the generator or Mains supply to be reduced.

Technical Features

- Management and control by microprocessor

- Charging curve of 3 states IUU type

- UNIVERSAL input voltage 90V to 250Vac (item 12V/40A, 12V/60A, 24V/30A,

24V/50A)

- Input voltage 230V ~ +10%/-15% (item 12V/20A, 24V/15A )

- Frequency 50/60Hz

- Output voltage Ubat ±1% ; output current Ibat ±10%

- Operating temperature -10 to + 45°C; storage temperature -20 to +70°C

- Charging curve selection by rotate switch for 5 different batteries types

- Sensor used to balance charging voltage according to temperature gaps (-27mV/°C)

- Automatic air vented cooling

- Protection Index IP 235

3

Advanced Charging Technique

Charging curves of the 3-state IUU type, with a boost phase and a floating phase.
The 3-state charging characteristic, used on boats everywhere, saves on charging time. In
addition, the charger can be adapted to all types of battery thanks to its 5 integral
charging curves supervised by a micro controller. Charge cycle starts on with the mains
power-up of product.

Boost Phase

Charging continues at constant current (charger Inom) until the battery reaches the
maximum boost voltage. This voltage is maintained until the charging current falls to
Inom/8 ~Inom/10 boost charge over short period (12 hours) from the mains power-up of
product. This phase makes it possible to supply the maximum amount of energy in the
least possible time.

Floating Phase

The charger supplies just the current necessary to keep the battery at a constant and stable
voltage (floating voltage). This charging mode allows 12-volt equipment to be used
continuously (water pump, refrigeration, auto pilot, radio, lights, etc.) without the
batteries discharging.
It means that the on-board circuit can be used while keeping the battery charge level
constant. WITHOUT BATTERY AND IN SPECIAL CIRCUMSTANCES, THE
POWER MASTER CHARGER SUPPLIES STABLE VOLTAGE.

General form of the charging curve (five possible levels according to battery type)

Top-up ChargeBalance Charge

Fast Charge

CURRENT

VOLTAGE

CAPACITY Ah

BOOTS

ABSORPTION

FLOATING

Charging Current

The nominal current shown in case of nominal voltage is the mean current supplied by
the charger.

Safety Devices

Electronic protection against:

- Output short-circuits

- Battery discharge in the event of mains failure

4

Disjonction protection against:

- Battery overvoltage or undervoltage

- Battery or charger overtemperature

Protection by fuses against :

- Mains input overload

- Battery polarity inversion

Anti-corrosion

Casing in aluminum with anti-corrosion paint.

Anti-impact

Resistance to impacts in normal use thanks to the 2 mm-thick casing (1,5mm for the
cover).

Ventilation

If the internal charger sensor exceeds 60°C, fan starts

Options

1. Battery Temperature Sensor (BTS):

Sensor is used to balance charging voltage according to temperature gaps, compared
with reference temperature 25°C. If temperature exceeds 45°C, charging stops and
LED of BTS OH flashes. Charging restarts when temperature is less than 45°C.

Procedure of connecting BTS is:

1. Disconnect the charger from the mains (MANDATORY). To avoid short-circuit,
disconnect the batteries.

2. Extract fixing screw from wires cover and remove it

3. Connect the sensor connector to the green terminal on the card (see figure A)

4. Connect charger to the mains

5. Fix the temperature sensor(s) on corresponding battery(ies) with double-sided
adhesive tape supplied with sensor.

To disconnect sensor from the charger, charger must be disconnect from the mains
before (even if the charger indicates a default).

CAUTION: In case of fault, charger switches off automatically. Disconnect charger from

mains then wait for approximately 10 minutes before starting it again.

2. Remote Control: It can be connected to the Power Master charger. All operating

controls and displays are available on the remote control unit.

Safety Instruction

A battery can generate gas in the case of high overcharge, that can be explosive.
Attention must be paid to produce no spark or flame near a battery on charge, arrange for
a well-ventilated room.

Power Master charger limits overcharges and reduces this risk.

z Excessive discharges are among the principal causes of premature wear.

Power Master charger prevents such excessive discharge. After every discharge,
(especially higher than 50%), recharging should not be deferred for a long time.

z Low and permanent overcharge is another cause of premature wear. The Power

5

Master Charger delivers the current necessary for battery charge and adapts itself to
supply the optimum end of charge.

z The accidental and violent overcharge or higher end of charge current produces early

destruction by excessive rise of temperature. The temperature should not exceed 50°C.
By the regulation of the current, the Power Master protects the battery from the
temperature rise at the end of charge.

It is advisable to

z Put batteries in a well ventilated area
z Not to smoke near batteries
z Take the battery manufacturer prescriptions into consideration

Accidental Leakage Current between Line And Earth

z Connections will be realized by an electrician or a professional installer.
z The charger must be connected to a system having a two-pole differential circuit

breaker with 30 mA sensitivity.

Accidental Leakage Current Between Charge Cir cuit and Earth

z To detect accidental leakage currents to earth, you must use a safety device outside

the charger.

z The rating and nature of the protection must be ensured by the installer.
z Special precautions are recommended on any installation where there is a danger of

electrolytic effects.

z Regulations require the presence of a battery cut-out on the output + pole and on

the output – pole.

Precautions Regarding Lightning Strike

In geographic zones exposed to a high risk of lightning strikes, it may be recommended

fitting a lightning conductor on the inlet side of the charger. Power Master will not take

charge of damaged caused by lightning strike.

Precautions Regarding Electromagnetic Interference

z Make sure the length of the cables and screening connections are kept as short as

possible.

z Separate the power supply cables from output cables.
z Cables must only carry the charger power supply. Branch or bridging connections in

order to supply another equipment are too be banned.

Installation

The location of the Power Master charger must be chosen by the following criteria:
Protection from unauthorized handling.
Dry dust free room, no condensation, no rodents.
Keep ventilation holes free. The ventilation of the Power Master is designed in such a
way that it will work most efficiently when mounted horizontally.
Before any connection, put the switch on the right charging curve.

1. Connect the positive battery on terminal marker +BAT 1 and open the entry of the

upper case to tighten it with screws.

6

2. Connect the negative battery cable to terminal marker –BAT and open the entry of the

upper case to tighten it with screws.

3. Do the same for batteries number 2 and 3 for +BTA 2 and +BTA 3. For a 3 outputs

charger, refer to the table below to choose conductor section.

BTS3BTS2BTS1

-BAT+BAT1+BAT2+BAT3

Battery fuse board:
Model No. 12V/20A 12V/40A 12V/60A
FUSE Atofuse (car) 1 x 25A 2 x25A 2 x 30A
Model No. 24V/15A 24V/30A 24V/50A
FUSE Atofuse (car) 1 x 15A 2 x15A 2 x 30A

WARNING: Check carefully the tightness of the battery connections to the charger (risk
if not properly tightened). Power Master will not take charge of damage caused by a

bad tightness of connections.
Don’t connect a charge distributor on an Power Master char ge r, 1 or 3 outputs.

4. Put the AC plug in the rear panel. The charger operates on sector 90V to 250 Vac -

50/60 Hz. Use preferably cable H07rn-F with 3 conductors. Earth lead to be
connected to the terminal on the unit.

Length 5m 10m 15m Sector flex section (5m)

Current 220V 110V

Puissance

(W)

30A 6 mm2 10 mm

2

16 mm

2

1.5 mm2 2.5 mm2 750

40A 10 mm2 16 mm

2

25 mm

2

1.5 mm2 1.5 mm2 500

50A 16 mm2 25 mm

2

35 mm

2

1.5 mm2 2.5 mm2 1200

60A 25 mm2 25 mm

2

35 mm

2

1.5 mm2 2.5 mm2 750

Main fuse board:

Model No.

12V/20A, 12V/40A, 12V/40A,

24V/15A, 24V/30A, 24V/50A

Temporized glass fuse 6.3x32mm 16A

7

Front Panel

15A/24V, 20A/12V

30A/24V, 40A/12V, 50A/24V, 60A/12V

LED Indicators

POWER: It is lit when the AC power has been input through the AC plug.
BOOST: It is lit as long as the battery is not fully charged at set voltage.
ABSORPTION: It is lit as long as the battery is not fully charged at set voltage.
FLOATING: It is lit when the battery is fully charged.
UV/OV:

Under Voltage---Deep battery discharge Ubat < 10V for 12V system and < 20V for 24V

system. If Ubat stays < 10V for 12V system and < 20V for 24 system
during more than 5 minutes, charger shuts down. To restart the charger:
disconnect the mains, wait few minutes and reconnect the charger on
mains.

Over Voltage--- Battery overcharge Ubat > 16V for 12V system and > 32V for 24V

system. If Ubat > 16V for 12V system and > 32V for 24V system
during more than 5 minutes, charger shuts down. To restart the charger:

disconnect the mains, wait few minutes and reconnect the charger on
mains.

OH: Over Heat---It is flashing when the heatsink of the charger reaches > 70℃. The

charger shuts down when the charger is > 80℃.

BTS OH: Battery Temperature Sensor Over Heat--- It is flashing when the BTS reaches

> 45℃. The charger shuts down when the battery temperature is > 50℃.

8

FUSE OPEN: Fuse is broken.

Switches Section (4 Battery Types and 1 User Define)

The great advances realized by manufacturers of batteries put at the disposal of users
batteries without maintenance, so it means a certain tranquillity for the user but impose,
however on the charger system, an exacting precision.
Every battery is designed according to particular technology and therefore calls for a
particular charging curve.
With Power Master battery charger, you can achieve this perfect match between battery
and charger using a switch, which is simply positioned according to the required,
charging curve.

Note: Do indicate the type of your battery when buying the charger, and position the

switch correctly before use.

Instruction of Charging Curve Selection

The user can very easily adapt the Power Master charger to the type of battery by rotate
switch used.
To modify configuration carryout the following steps:
STEP 1: Disconnect charger from the mains. To avoid short-circuit, disconnect the
batteries.
STEP 2: According to 4 different battery types and desired charge current (30%, 70% and
100%), choose the rotate switch from 1 to C. If the used battery is not in 4 listed
battery types, User Define is available.

Battery Type U Boost U Float

Charge

Current

Rotate

Switch

14.4V 13.5V 100% 1

14.4V 13.5V 70% 2

Sealed lead, maintenance-free
gel type

14.4V 13.5V 30% 3

14.2V 13.8V 100% 4

14.2V 13.8V 70% 5

Classical lead open

14.2V 13.8V 30% 6

14.6V 14.0V 100% 7

14.6V 14.0V 70% 8

Lead calcium
(standard charge )

14.6V 14.0V 30% 9

16.0V 13.8V 100% A

16.0V 13.8V 70% B

Lead calcium *

DEEP DISCHARGE

16.0V 13.8V 30% C

─ ─ 100% D
─ ─ 70% E

User Define

─ ─ 30% F

User Define: Use the switches of the BOOST VOLTAGE and FLOAT VOLTAGE to
choose desired voltages from the following tables.

9

BOOST VOLTAGE Selection

Rotate
Switch

Boost

Volt.

Rotate
Switch

Boost

Volt.

Rotate
Switch

Boost

Volt.

Rotate
Switch

Boost

Volt.

0 14.4V 5 14.9V A 15.4V F 14.3V
1 14.5V 6 15.0V B 15.6V
2 14.6V 7 15.1V C 15.8V
3 14.7V 8 15.2V D 16.0V
4 14.8V 9 15.3V E 14.2V

FLOAT VOLTAGE Selection

Rotate Switch Floating Volt. Rotate Switch Floating Volt.

0 13.5V 5 14.0V
1 13.6V 6 13.1V
2 13.7V 7 13.2V
3 13.8V 8 13.3V
4 13.9V 9 13.4V

STEP 3: Connect charger to the mains.

Example:
To use the Power Master charger of 12V/40A to charge a battery of Classical lead open at
desired charging current 28A, users should choose rotate switch of battery type to be “5”.

DC Power Supply

Power Master charger can not only charge the battery but also supply DC power directly.
The desired voltage can be set by the following steps.

STEP 1: Choose the rotate switch of BATTERY TYPE to be“0＂.
STEP 2: Use the rotate switch (0~F) of BOOST VOLTAGE to set the first two digits of

desired voltage. Refer to the below table for what 0~F represents.

Rotate
Switch

Boost

Volt.

Rotate
Switch

Boost

Volt.

Rotate
Switch

Boost

Volt.

Rotate
Switch

Boost

Volt.

0 13.0V 5 16.0V A 16.0V F 16.0V
1 14.0V 6 16.0V B 16.0V
2 15.0V 7 16.0V C 16.0V
3 16.0V 8 16.0V D 16.0V
4 16.0V 9 16.0V E 16.0V

STEP 3: Use the rotate switch (0~9) of FLOAT VOLTAGE to set the decimal of desired
voltage. Refer to the below table for what 0~9 represents.

Rotate Switch Floating Volt. Rotate Switch Floating Volt.

0 0.0V 5 0.5V
1 0.1V 6 0.6V

10

2 0.2V 7 0.7V
3 0.3V 8 0.8V
4 0.4V 9 0.9V

Example:
To set the desired DC power supply of 14.3V, firstly, choose the rotate switch of battery
type to be“0＂and then choose the rotate switch of boost voltage to be“1＂; finally,

choose the rotate switch of float voltage to be“3＂.

BTS/Remote Control

It is a port for phone jack of the battery temperature sensor and upcoming remote control
to be connected.

Troubleshooting Guide

Problem and Symptoms Possible Cause Solution

No alternative current or

main fuse is melted down

Check the fuse and replace
it

No output voltage and/or
intensity

Main or generating unit too

weak

Check the input voltage

Battery consumption > power

of the charger

Reduce the consumption on
the battery

Charger delivers a weak
output voltage but a max.
intensity

One or several elements of
the battery present a

short-circuit

Check that there 's no
increase of battery
temperature

Battery is almost totally

charged

Check that the charger is on
a floating mode

Intensity of charge is too
weak < 10%

Alimentation is too weak Check the input voltage

Consumption on the battery
during the charge is too
important

Decrease the consumption

Time of charge is too short

Choose a more powerful
charger

Battery temperature too weak Use a temperature sensor

Battery is never totally
charged

Defective battery Change the battery
Loss (emission of gas)

Change the battery or check
the level of water

Battery is quickly empty

Sulfate on / stagnation

Charge / discharge several
time the battery or check
the charging curve or
replace the battery

Defective battery Replace the battery

Battery is hot/emission of
gas

Temperature of the battery is
too high

Use a temperature sensor
and/or check the charging
curve

11

The charger is near to the

"switch off" temperature

Ventilate the charger
Red LED DEFAULT
flashes

Battery temperature is too
high (with a temperature
sensor)

Check the charging curve

and placed the battery in a

ventilated area

All LEDS are flashing but
the charger doesn’t charge

Default of the battery which
is in deep discharged or
polarity inversion of the
battery

Check the connection of the

battery, the polarity and

the output fuse

Problem and Symptoms Possible Cause Solution

All LEDS are flashing but
the charger doesn't charge

DEFAULT

Check the battery

connections and the

connection of display, and

check the output fuse
No LED is lighting when
the charger is connected to
the main

DEFAULT

Check the main input, the

connection of display and

the fuses.

During the charge, all
LEDS are switched off

Stop because of the thermic
security or battery voltage <
9 V
( 18V for a 24V battery )

disconnect the charger, wait

20 minutes and connect to

the main

12

Specifications

Output: 12V
Model No. PM-SBC-2012 PM-SBC-4012F PM-SBC-6012F

Input Voltage

Input voltage

230V ~

+10%/-15%

Universal input:

90V to 250V

Output Voltage

12V

Charging Capacity

20A 40A 60A

Frequency

50Hz/60Hz

Output Patterns

1 or 3

Input Voltage U bat

+/-2%

Output Current I bat

+/-10%

Charging Curve Type

3 states IUU type

(Boost Charge, Absorption Charge, Floating Charge)

Charging Curve Selection

By SWITCH for 5 different battery types:

Classical lead open, sealed lead/gel, lead calcium

standard charge, lead calcium deep discharge, user define

Working Temperature

-10℃ ~ +45℃

Storage Temperature

-20℃ ~ +70℃

Protection Feature

Against output short-circuit, battery discharge in the event of

mains failure, mains input overload, battery polarity inversion

Protection Options

Battery or charger overtemperature

(Temperature sensor)

Dimensions

310x200x70 mm 400x250x80mm 400x250x80 mm

Weight

3 kgs 6 kgs 6 kgs

13

Output: 24V
Model No. PM-SBC-1524 PM-SBC-3024F PM-SBC-5024F

Input Voltage

Input voltage

230V ~

+10%/-15%

Universal input:

90V to 250V

Output Voltage

24V

Charging Capacity

15A 30A 50A

Frequency

50Hz/60Hz

Output Patterns

1 or 3

Input Voltage U bat

+/-2%

Output Current I bat

+/-10%

Charging Curve Type

3 states IUU type

(Boost Charge, Absorption Charge, Floating Charge)

Charging Curve Selection

By SWITCH for 5 different battery types:

Classical lead open, sealed lead/gel, lead calcium

standard charge, lead calcium deep discharge, user define

Working Temperature

-10℃ ~ +45℃

Storage Temperature

-20℃ ~ +70℃

Protection Feature

Against output short-circuit, battery discharge in the event of

mains failure, mains input overload, battery polarity inversion

Protection Options

Battery or charger overtemperature

(Battery Temperature Sensor)

Dimensions

310x200x70 mm 400x250x80mm 400x250x80 mm

Weight

3 kgs 6 kgs 6 kgs

CHARGE

CURRENT

15A
20A
30A
40A
50A
60A

OUTPUT

VOLTAGE

12VDC
24VDC

PM –SBC- 20 12