AL Tech CB Series User manual

Instruction Manual CB120-240-280-480W_R13_A24.AAA
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
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CB Smart Battery Chargers
Instruction Manual
B120W CB240W CB280W CB480W: Smart Battery Chargers
Thank you for having chosen one of our products for your work.
We are certain that it will give the utmost satisfaction and be a notable help on the job.
General Description
CB series is Charge & Testing devices in “Switching
technology” and “Battery Care philosophy”, since many
years parts of the know-how ADEL system. This
technology led to the development of this advanced multi-
stage battery charging, completely automatic and suited to
meet the most advanced requirements of battery
manufacturers. The Battery Care concept is base on
algorithms that implement rapid and automatic cycle of
battery charging, battery charge optimization during time, flat batteries recovery and real time diagnostic during
installation and operation. The Real Time Auto-diagnostic system, monitoring battery faults such as, elements in short
circuit, accidental reverse polarity connection, disconnection of the battery, they can easily be detected and removed
by help of Blink Code of Diagnosis Led; during the installation and after sell. Each device is suited for all battery
types, jumper selection sets a predefined curves for: Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd and Li-Ion. A
rugged casing with bracket for DIN rail mounting provide IP20 protection degree.
Main Characteristics
•Input: Single-phase 115 –230–277 Vac
•Output Battery: charging: 24 Vdc 10A –20 A
12 Vdc 10A –35 A
•Suited for the following battery types: Open Lead Acid, Sealed
Lead Acid, Lead Gel, Ni-Cd and Li-Ion
•Automatic diagnosis of battery status and battery Life Test
function (Battery Care)
•Switching technology- High efficiency
•Three charging levels: Iuou Bulk, Absorption, Float
•Protected against short circuit, Over Load and inverted polarity
•Output dry contact for discharged or damaged battery
•Output dry contact for Mains or Back-Up
•Protection degree IP20 - DIN rail; Space saving
•Temperature Compensated Charging
•ADELBus connection: ModBus (RTU)
Safety and warning notes
WARNING –Explosion Hazard Do not disconnect Equipment unless power has been switched off or the area is
known to be non-hazardous.
WARNING –Explosion Hazard. Substitution of components may impair suitability for class I, Division 2.
WARNING –Switch off the system before connecting the module. Never work on the machine when it is
live. The device must be installed in according with UL508 or UL 60950. The device must have a suitable
isolating facility outside the power supply unit, via which can be switched to idle. Danger of fatal Injury!
Connection (terminal and wiring):
Cable Connection: The following cable cross-sections may be used:
Solid
(mm
2
)
Stranded
(mm
2
)
AWG Torque (Nm)
Stripping
Length
All In One
(Size)
1 Phase L N PE
Input AC
1 Phase L N PE
Input AC
In:
0.2 –2.5
0.2 –2.5
24 –14
0.5 –0.6 Nm
7 mm
Size 1 and 2
4.0
6.0
30 –10
0.8 –1.0 Nm
7 mm
Size 3 and 4
Ou
t:
0.2 –2.5
0.2 –2.5
24 –14
0.5 –0.6 Nm
7 mm
Size 1 and 2
4.0
6.0
30 –10
0.8 –1.0 Nm
7 mm
Size 3 and 4
Signal
:
0.2 –2.5
0.2 –2.5
24 –14
0.5 –0.6 Nm
7 mm
All types
The connection is made by the screw type 2.5 mm2 or 4.0 mm2 terminal blocks. Use only copper cables that are
designed for operating temperatures of > 75 °C. Wiring terminal shall be marked to indicate the proper connection
for the power supply. Output Power connections:
ENERGY
SAVER

Normal connection: Battery & Testing Charger:
Typical application for CBxxyy device:
N°1 battery (12 Vdc) for CB12yy;
N°2 battery (12 Vdc) connected in Series for CB24yy;
“Redundancy” Connection
It's possible to request the Redundancy option for the model
CB2420AR. Just connect the two CB via the RJ45 cable to AUX2
and power on them (also at different times), automatically one of
the CB becomes the real battery charger (indicated by a flashing
LED diagnosis according to the usual frequency) while the
second holds steady on the LED diagnosis. On both pieces is
active the management of alarms. If the piece that charge turns
off (or break!) the second automatically begins charging. If there
is no communication between the two CB has alarm with flash =
code 11 blinks, under these conditions both the CB trying to
charge the battery (situation not recommended) to which it is
appropriate to human intervention, just reconnect the two pieces
and the situation normalizes.
Auxiliary Load Connection (Size 4)
Typical application for Auxiliary device, one output for Load
“DC Bus”, one Input/Output for connection to the battery.
N°1 battery (12 Vdc);
N°2 battery (24 Vdc) connected in Series;
Operating and Display Element:
No. 1: Battery Connection Port:
Connect the battery between pin. 3 (–) and 4 (+)
One battery (12 Vdc) for CB12yy;
Two battery (12 Vdc) connected in Series for CB24yy
No. 2: Output Load: (Size 4)
If Present on the device
Connect this Output to the load 1 (–). 2 (+).
(Output Load It is to supply Auxiliary Load)
No. 3: Charging Level Current:
In order to protect the battery from excessive charging currents, the device allows you to limit the maximum charge current
by adjusting the trimmer. It allows you to limit from max In up to 20% of current In. To determine the
maximum battery charge current, see the battery manufacturer's Data Sheet, If it is not possible,
consider that on average the maximum charge current is 10% of Ah's rated battery current; The data
is suitable for both Lead Acid and NiCd batteries.
3
Size 1
1
4
5
6
7
8
11
10
18
Size 2
6
7
8
3
11
10
18
1
4
5
Size 3
10
1
18
6
7
8
3
11
13
5
4
Size 4
10
2
1
5
4
11
17
15
6
8
9-12
16
14
13
18
3
7
15
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual

No. 4, 5 Signal Ports (Output Isolated):
Connections for,
No. 5: MAINS OR BACKUP: Input Mains On/Off. Contact: 5,6,7
No. 4: LOW BATTERY, BATTERY REPLACEMENT, FAULT BATTERY or FAULT SYSTEM Contact: 8,9,10
Relay Contact Rating:
Max.DC1: 30 Vdc 1 A; AC1: 60 Vac 1A : Resistive load (EN 60947-4-1)
Min.1mA at 5 Vdc: Min. permissive load
Signal Output port
true table:
Port N°5 - Led N°6
Mains/Back-Up
Port N°4 - Led N°7 Fault
Battery
5-6 Closed
5-7 Closed
8-9 Closed
(OK)
8-10 Closed
Mains Input Vac
ON
■- led Off
■- led Off
OFF
■- led On (1)
■- led Off
The battery in
BackUP it is less than
30% cap?
YES
■- led On
■- led On
NO ■- led On ■- led Off
Battery or system
Fault?
YES
■- led Off
■- led On (2)
NO
■- led Off
■- led Off
Note:
(1) For better efficiency of the system, filter relay Mains/Back up with a delay of at least 5 seconds before give alarm
Main Lost, example: connection to PLC.
(2) See Diagnosis Led
No. 6, 7 and 8 Display Signals
No.6: Led Mains/Back Up: Input Mains On/Off
No.7: Led Low Battery(capacity less than 30%), Fault connections systems, Battery replacement.
No.8: Led DIAGNOSIS: Battery charge mode,
Led Diagnosis. Diagnosis of the system through “blinking code” signal Light
State of Charge
Monitoring
Control
Chart:
State
Led
DIAGNOSIS
(No.8)
LED
BATTERY
FAULT (No.7)
Charging
Type
Float
1 Blink/2 sec
OFF
Absorption
1 Blink/sec
OFF
Boost
2 Blink/sec
OFF
Recovery
5 Blink/sec
OFF
Fault Battery / Fault System
System Auto
Diagnosis
Reverse polarity or high battery Voltage
(over 32.5Vdc for CB 24xxA)
1 Blink/pause ON
Battery No connected
2 Blink/pause
ON
Element in Short Circuit
3 Blink/pause
ON
Over Load or short circuit on the load
4 Blink/pause
ON
Bad battery; Internal impedance Bad or Bad battery wire
connection
5 Blink/pause ON
Life test not possible
6 Blink/pause
ON
Boost condition; battery discharge after 4 min. of overload.
8 Blink/pause
ON
Internal fault
9 Blink/pause
ON
Low battery (under 18.5Vdc for CB 24xxA) Only if started
from battery, no Mains input, from Jumper N°5 or Push
Bottom
10 Blink/pause ON
MODBUS error
11 Blink/pause
ON
Life test not possible; Parallel mode on Slave Device
12 Blink/pause
ON
Bad battery wire connection; Parallel mode on Slave Device
13 Blink/pause
ON
Boost condition; battery discharge after 4 min. of overload;
Parallel mode on Slave Device
15 Blink/pause ON
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual

Size 4
No. 9, 12: Start From Battery Only; No Mains Vac (Size 4)
No. 9: Push-bottom, for 3 sec., in the front panel for switch ON the system without the “Mains input Vac”
but only the battery connected.
No.12: It is also available the same function for remote start from the battery, via RTCONN cable
connected in the Push-bottom mounted on front Panel of the external system.
N.B.: This Function it is present only if it is enabled Jumper in Option position
No. 10: Input AC Port pin. L –N:
1 Phase Switching Power Supplies L, N, PE .
Size 2 and Size 3 BRIDGE ONLY for input 115 Vac, and connect L, N, PE .
No. 11: Auxiliary Output “AUX 1”
Remove the window label to find the connector.
It is possible to connect the Temperature sensor probe and apply it on the battery.The function of the probe is for
temperature battery compensation. With this it is possible to active the specifications of the EN54-4 fire norm.
Battery Temperature Compensation Charge (not for NiCd)
Connecting to Auxiliary Output AUX1 the cable RJTEMP (supplied separately), the CB will vary the voltage of
battery charging depending on the temperature:
Fast Charge
Float charge
+/-5mV/°C x n. of Cells from -8°C to +45°C
+140mV/Cell ÷ -200mV/Cell compared to the
value at 20°C
+/-3mV/°C x n. of Cells from -20°C to +45°C
+120mV/Cell ÷ -120mV/Cell compared to the
value at 20°C
The device stop to charge the battery If the temperature is less than -20°C or greater than +45°C. The alarm fault
battery could be signalled by 7 blink code.
The sensor placed on cable RJTEMP must be applied on the battery.
No. 13: Auxiliary Output “AUX 2” (Size 3-4)
Present only in Sizes 3 and Sizes 4, connection MODBUS via RJ45 connector. See instruction MODBUS
communications protocol. (CANBUS to be implemented).
No. 14: Auxiliary Output “AUX 3” (Size 4)
Present only in Sizes 4. The function is the same of Auxiliary Output “AUX 2”
No. 15: Buffering Time Setting (Size 4)
On model Size 4 is possible to set a buffering time. It can be selected by setting the desired value on the rotary
switch 15. Buffering time is initiated when the mains is switched OFF. The LOAD output will be ON for the selected
time.
Switch position
0
1
2
3
4
5
6
7
8
9
Buffering Time (min.)
∞
0.5
2
5
10
15
20
30
45
60
If the switch is in position 0, the LOAD output will be in ON state until the battery is completed discharged. Any way
to prevent damage risks, the unit disconnects the batteries when a minimum voltage level is reached.
No. 16: Bus Termination (Size 4)
Read the MODBUS/CANBUS instruction manual to learn about the operational functions available.
Deepswitch Setting always active during all states of the system.
No. 17: Select Output Voltage (Size 4)
Caution: Switch off the system before Setting the Jumper
Output Voltage Selection 24 Output Voltage
Output Voltage Selection 12 Output Voltage
No. 18: Battery Management Configurations
Preliminary Operations: One device for all battery types.
Completely automatic, all devices are suitable to charge most batteries types thank to User Selectable charging
curves. They can charge open lead acid, sealed lead acid, Gel,Ni-Cd and Li-Ion. It is possible to change or add
other charging curves connecting the device to a portable PC.
Size 1,2,3
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual

Caution:Switch off the system before Setting the jumper.Only jumper in position 6 is Refreshed also with power ON.
Don’t use Ni-Cd charging configuration in battery less than 7 Ah.
Notice:
1. Do not leave the jumper in position 5; otherwise, in Backup mode, the battery discharges completely close to zero.
2. Contact closed: Auxiliary LOAD enabled
Contact open: Auxiliary LOAD disabled.
This function permit to supply all electronic Load in Short Circuit, Over Load Protection.
In this Way the device it is free to detect all parameters on the battery side.
3. Jumper present in Fast Charge means also that every 288h, the device go in “Cycling Refresh Charging”. This mode
continue for 85 minutes at the same voltage condition: 2.4V/Cell; for Lead Acid Batteries.
4. Please note that it is possible to use lithium-charging curve just with a single BMS AND Only by custom request
5. By DPY351 or ADELViewsystem it is possible configure a Customized Charging Curve. After programming it is
possible disconnect the programmer an use the device as standalone device.
Battery Type Selection
Jumper
Position
(Size 1)
Jumper
Position
(Size 2)
Jumper Position
(Size 3)
Dip Switch
Position
(Size 4)
Float charge
(Volt/Cell)
Fast charge
(Volt/Cell)
Open
Lead2.232.40
(AGM) Low2.252.40
Gel Battery 2.302.40
NiCd
1.4/cell
(12V:10 cells)
(24V:20 cells)
1.5V/cell
(12V:10 cells)
(24V:20 cells)
Li-Ion (4)
3.45
(12V:4 cells)
(24V:8 cells)
3.65
(12V:4 cells)
(24V:8 cells)
Custom Charging
Curve (5)
Config. by DPY351 or
ADELViewsystem.
Functional Setting
Function
Battery Life test
ON
Jumper present or dip switch
ON: Life test enabled (not for
NiCd)
Fast Charge
Enable (3)
Jumper present: Fast Charge
enabled. It is possible remote
Fast Charge enabling by
RTCONN cable
Power Supply
Enabling
Provide Power Supply
Function On Battery Output
“Start from
Battery” (without
Input Mains) (1)
Switch ON the system without
the “Mains In Vac”, only the
battery is connected. For
connection to external Push
button use RTCONN cable
Load Enabling
(2) Present in CB122410A (Size4)
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual

Battery Care
The Battery Care philosophy is base on algorithms that implement rapid and automatic charging, battery charge
optimization during time, flat batteries recovery and real time diagnostic during installation and operation. The Real
Time Auto-diagnostic system, monitoring battery faults such as, elements in short circuit, accidental reverse polarity
connection, disconnection of the battery, they can easily be detected and removed by help of Blink Code of Diagnosis
Led; during the installation and after sell. Each device is suited for all battery types, by means of jumpers it is possible
setting predefined curves for Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd and Li-Ion.They guarantees battery
reliability in time by continuously testing the internal impedance status, avoids any possible risk of damages and
grants also a permanent, reliable and safe connection of the battery to the power supply. The system, through a
battery stimulation circuit with algorithms of evaluation of the detected parameter, is able to recognize sulphated
batteries or batteries with a short-circuited element.
Battery Test: Automatic. Every 60 sec. check battery connection. Every 220 minute in Float charge, make the test of
the battery efficiency. The fault is signalized with relay commutation and diagnosis led blinking.
Check for accidental disconnection of the battery cables:
All In One detects accidental disconnection and immediately switched off the output power.
Battery not connected:
If the battery is not connected no output power.
Test of quality wire connections:
During Float charge the quality (resistance) on the battery connection is checked every 60 sec. This to detect if the
cable connection has been properly made.
Battery in Open Circuit or Sulphated:
Every 220 minute. The CB tests of internal impedance, in Float charging mode.
Reverse Polarity check:
If the battery it is connected with inverted polarity, CBis automatically protected.
Test of battery voltage connections:
Appropriate voltage check, to prevent connection of wrong battery types, more or less than the nominal voltage.
End of Charge check
When the battery it is completely full, the device automatically switch in Float charging mode.
Check for Battery Cells in short circuit
Thanks to specific algorithms of evaluation, the CBs recognize batteries with cells in internal short circuit.
In Float charge every 220 minute test of element in short circuit.
Diagnosis of battery and device
All CB devices support the user during installation and operation. A Blink code of Diagnosis Led allows to
discriminate among various possible faults.
Error conditions, “LED Battery Fault”ON and “LED Diagnosis”blinking with sequence; see Display Signal section.
Protection Features
On the primary side: the device is equipped whit an internally fuse. If the internal fuse is activated, it is most
probable that there is a fault in the device. If happen, the device must be checked in the factory.
On the secondary side Battery and load: The device is electrically protected against short circuits and overload.
Inversion polarity: the module it is automatically protected against inversion of battery polarity and connection of
load inverted.
Over current and output short circuit: the unit limits the output current (see the technical data).
Deep discharge: not possible. The unit disconnects the battery when a minimum voltage level is reached.
Thermal behaviour
Surrounding air temperature 50°C. For ambient temperature of over 50°C, the output current must be reduced by
2.5% per °C. Max 70°C At the temperature of 70°C the output current will be 50% of In. The equipment does not
switch off in case of ambient temperature above 70°C or thermal overload. The devices are protected for Over
temperature conditions “worst case”; in this situations the device Shut-down the output and automatic restart when
temperature inside fall.
Charging Curve
Automatic multi-stage operation and real time diagnostic allows fast recharge and recovery of deep discharged
batteries, adding value and reliability to the system hosting the CB device. The type of charging is Voltages
stabilized and Current stabilized IUoUo. Five charging phases are identified by a flashing code on a Diagnosis LED.
To maintain the Output Load in lower Voltage state, don’t put jumper in position 6, in this case no boost charge but
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual

only Float charge. Fast/Bulk Charge means also that every 288h, the device go in “Cycling Refresh Charging” for 85
minutes at 2.4V/Cell.
Standard and Certifications
Electrical Safety For Mounting:
Device assembling: UL508, IEC/EN 60950 (VDE 0805) and EN 50178 (VDE 0160). Installation according: IEC/EN
60950. Input / Output separation: SELV EN 60950-1 and PELV EN 60204-1. Double or reinforced insulation. Safety of
Electrical Equipment Machines: EN 60204-1.
In According to EMC 2014/30/UE and Low voltage directive 2014/35/UE
Safety Standards: EN IEC 62368-1: 2014/AC:2015
EMC Standards Immunity:
EN 61000-4-2, EN 61000-4-3, EN 61000-6-2, EN 61000-4-4, EN 61000-4-5.
EMC Standards Emission:
EN 61000-6-4, EN 61000-6-3, EN 61000-3-2 (see data sheet for each device)
Conformity to:
EN60950 / UL60950-1 and CSA C22.2 No. 60950-1-07 (Information Technology Equipment) –Safety –Part1: General
Requirement.
IEC/EN 60335-2-29 Battery chargers
Electrical safety EN54-4 Fire Detection and fire alarm systems;
DIN41773 (Charging cycle)
Approved:
Devices:CB1210A,
EN60950 / UL60950-1 and CSA C22.2 No. 60950-1-07 (Information Technology Equipment) –Safety –Part1: General
Requirement.
Rail Mounting:
All modules must have a minimum vertical and horizontal distance of 10 cm to this power supply in order to
guarantee sufficient auto convection. Depending on the ambient temperature and load of the device, the
temperature of the housing can become very high.
Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual

Altech Corp.®•35 Royal Road •Flemington, NJ 08822-6000 •P 908.806-9400 •F 908.806.9490 • www.altechcorp.com
CB Smart Battery Chargers
Instruction Manual