Meanwell PB-1000-12 User manual

PB-1000
Instruction Manual

PB-1000 Instruction Manual
1
1.Main Specifications
..
PB-1000-12 PB-1000-24 PB-1000-48
MODEL
BOOST CHARGE VOLTAGE
FLOAT CHARGE VOLTAGE
BATTERY TYPE
LEAKAGE CURRENT FROM
BATTERY (Typ.)
RECOMMENDED BATTERY
CAPACITY(AMP HOURS)(Note 3)
OUTPUT
VOLTAGE RANGE
FREQUENCY RANGE
EFFICIENCY (Typ.)
POWER FACTOR (Typ.)
INPUT
ENVIRONMENT
INRUSH CURRENT (Typ.)
LEAKAGE CURRENT
OVER TEMPERATURE
SHORT CIRCUIT
REVERSE POLARITY
SAFETY STANDARDS
HARMONIC CURRENT
EMI CONDUCTION & RADIATION
SAFETY &
EMS IMMUNITY
EMC
(Note 2)
WITHSTAND VOLTAGE
ISOLATION RESISTANCE
WORKING TEMP.
WORKING HUMIDITY
STORAGE TEMP., HUMIDITY
TEMP. COEFFICIENT
VIBRATION
OVER VOLTAGE
PROTECTION
AC CURRENT (Typ.)
14.4V 28.8V 57.6V
13.8V
Open & Sealed Lead Acid
<1mA
200 ~ 600Ah
27.6V 55.2V
34.7A 17.4A
120 ~ 350Ah 60 ~ 175Ah
90 ~ 264VAC 127 ~ 370VDC
47 ~ 63Hz
85%
0.95/230VAC 0.98/115VAC at full load
88% 89%
12A/115VAC 5.2A/230VAC
25A/115VAC 50A/230VAC
<3.5mA / 240VAC
16 ~ 18V 32 ~ 35V 64.5 ~ 69.5V
Protection type : Shut down o/p voltage, re-power on to recover
80 5 (12V), 85 5 (24V,48V) (TSW1: detect on heatsink of power transistor)
85 5 (12V),75 5 (24V,48V) (TSW2 : detect on heatsink of o/p diode)
Protection type : Shut down o/p voltage, recovers automatically after temperature goes down
YES, protected by internal circuit
YES, protected by internal circuit
UL60950-1, TUV EN60950-1 approved
Compliance to EN55022 (CISPR22)
Compliance to EN61000-3-2,-3
Compliance to EN61000-4-2,3,4,5,6,8,11; ENV50204, EN55024, light industry level, criteria A
I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVAC
I/P-O/P, I/P-FG, O/P-FG:100M Ohms/500VDC 25 70%RH
-20 ~ +60 (Refer to output load derating curve)
20 ~ 90% RH non-condensing
-40 ~ +85 , 10 ~ 95% RH
0.05%/ (0 ~ 50 )
10 ~ 500Hz, 2G 10min./1cycle, 60min. each along X, Y, Z axes
MTBF 127.4Khrs min. MIL-HDBK-217F (25 )
300*184*70mm(L*W*H)
DIMENSIONOTHERS
NOTE
PACKING 3.5Kg; 4pcs/15Kg/1.83CUFT
1. All parameters NOT specially mentioned are measured at 230VAC input, rated load and 25 of ambient temperature.
2. The power supply is considered a component which will be installed into a final equipment. The final equipment must be re-confirmed that it still meets
EMC directives.
3. This is Mean Well's suggested range. Please consult your battery manufacturer for their suggestions about maximum charging current limitation.
FUNCTION
REMOTE CONTROL
BATTER BANKS
FAST CHARGE
OUTPUT OK
TEMPERATURE COMPENSATION
CHARGER OK
Open: Normal work Short: Stop Charging
2 banks (A & B)
2 / 8 stage selectable
Relay contact rating(max.): 30V/1A resistive ; "Short" when the battery is full, "Open" when the battery is still charging
Relay contact rating(max.): 30V/1A resistive ; "Short" when the unit is working properly, "Open"when the unit is failure or the protection function is activating
By NTC, compensate both banks at the same time
OUTPUT CURRENT 60A

2
1.The charger should be turned OFF prior to battery connection. Suitable wire gauge should be chosen based on rated charging
current of the PB-1000 unit. Double check battery polarity before making the battery connection. Positive terminal of the charger
must be connected to "+" of the battery and negative terminal to "-" of the battery. Also, make sure the positive and negative
terminals of the charger are not accidentally shorted together.
2.After connecting the output cables, flick the ON/OFF (0/-) switch to the ON (-) position. The indicator light on the switch will turn ON.
Assembly Guidelines:
1.Designed for charging lead acid battery.
2.Must be installed in a dry and well ventilated area. It should not be exposed to rain or snow.
3.The cables between charger and battery should be kept as short as possible to prevent excessive line drop. Too much line drop will
lead to longer charging period.
4.Please make sure charging voltage and current meets battery specification.
5.Refrain from connecting new and old batteries in series.
6.PB-1000 should be in the OFF mode before making battery connection or disconnection.
7.Three years warranty is provided under normal operating conditions. Failure resulting from improper operation will result in
cancellation of warranty.
Notes on Operation:
AC INLET
Battery B
Positive
Battery A
Positive
WARNING : Please check
battery polarity
before connection
Common
Negative
Fan
Ventilation
Hole
Figure 2.1 Front Panel
Figure 2.2 Back Panel
LED
Indicator
Function
Connector
2/8 stage
selection switch
ON/OFF SWITCH
ON
AC INPUT
OFF
A
{
BA
B
12
34
56
78
9 10
8 Stage 2 Stage
+
+
Battery A
Battery B
-
-
2.Front and back panel
12
34
56
78
9 10

8 stages charging differ from 2 stages with the addition of pulse, soft start, analysis, recond, float, and maintain stages. 2 stages
provide simple and quick charging. On the other hand, 8 stages will allow charging to maximum capacity. User can select between 2 or
8 stages depending on actual requirement.
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). When charging current decrease to less than 10% of
max. LED indicator will turn Green indicating a full charge.
6 Explanation of Operation Logic (Charging stages):
6.1 "2" stage charging (Selection switch to "2" stage)
.
3.Derating Curves
3.1 Charging current VS Temperature
AMBIENT TEMPERATURE ( )
LOAD (%)
20
40
60
80
100
-20 0 10 20 30 40 50 60 70 (HORIZONTAL)
Color of LED
Battery status
Orange
Charging
Green
Battery full
Red
Fail
Pin No. Function Description
1,2
3,4
5,6
7,8
9,10
RY13
RY14
RY15
RC- / RC+
GND / RTH
Relay contact rating(max.) : 30V/1A resistive. ; "Short" when the battery A is full, "Open" when the
Relay contact rating(max.) : 30V/1A resistive. ; "Short" when the battery B is full, "Open" when the
Relay contact rating(max.) : 30V/1A resistive. ; "Short" when the unit is working properly, "Open"
battery A is still charging.
battery B is still charging. If the temperature sensor is not used, the charger still works normally.
when the unit is failure or the protection function is activating.
Temperature sensor comes along with the charger can be connected to the unit to allow temperature
Turn the output on and off by electrical or dry contact between pin 10 (RC+) and pin 9(RC-).
compensation of the charging voltage. If the temperature sensor is not used, the charger still works
normally.
Open : Normal work , Short : Stop charging.
4.Function Description of CN100
5.LED Indication
Types of failure: 1
4
5
2 3Battery disconnected
Incorrect battery voltage (e.g. PB-1000-12 connected to 24V battery)
Activation of protection function (e.g. OTP, OVP, and Short)
Damaged battery Reverse polarity
3

4
Advantage of pulse stage: Use pulse current to revive aged battery.
Advantage of recond stage: Allow full charge of battery.
Advantage of Float and Maintain stage: After LED turns green, maintenance charge is provided so the battery is always in a full
state. User will have access to a full battery whenever it is disconnected from the charger.
6.2 "8" stage charging (Selection switch to "8" stage)
Charge
Current
stage 1 stage 2
Charge
Voltage
Pulse Soft
Start
Color of
LED
Start Pulse
Pulse
A Battery
B Battery
A Battery
B Battery
A Battery
B Battery
A Battery
B Battery
A Battery
B Battery
A Battery
B Battery
A Battery
B Battery
A Battery
B Battery
Soft
Start
Soft
Start
Figure 6.2 8 Stage Charging Curve
stage 3 stage 4 stage 5
Constant
Current
Constant
Voltage
Analysis
Orange
Constant
Constant
Constant
Constant
Current
Current
Voltage
Voltage
stage 6 stage 7
Recond Float
Green
Float
Float
A/B Maintain Cycle
Analysis
Analysis
Recond
Recond
stage 8
Maintain
Maintain
Maintain
State
Vboost 14.4V
PB-1000-12
28.8V 57.6V
PB-1000-24 PB-1000-48
Charge Current
Constant Current
stage 1 stage 2
Constant Voltage Battery Full
Start
Charge Voltage
100%
10%
Orange Green
Color of LED
boostV
Constant
Current 60A 34.7A 17.4A
Figure 6.1 2 Stage Charging Curve

5
A
B
1 2
34
56
78
9 10
A
A A
B
B B
8 Stage
8 Stage 8 Stage
++
+ +
Battery ABattery B
Battery A Battery B
--
- -
2 Stage
2 Stage 2 Stage
AB
8 Stage
++
Battery ABattery B
--
2 Stage
Switch
Turn right
Turn left
Charging mode
2 stage charging
8 stage charging
A
A
A
B
B
B
1
1
1 2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
7
7
7
8
8
8
9
9
9 1
1
1 0
0
0
8 Stage 2 Stage
The charger features user selectable 2 or 8 stage charging. The charging profile is selected by moving the slide switch on the back
panel.
7.3 2 or 8 stage Charging mode Select
The charger can be turned ON/OFF by using the "Remote Control" function.
7.Function description
7.1 Remote Control
The charger may be hooked up two battery banks (A and/or B). Connect the battery bank(s) as below. If you are connecting 2
battery banks in the same time, keep in mind that they must share a common ground.
7.2 Two Battery Banks
A
B
1 2
34
56
78
9 10
SW
910
CN100
RY13
RY14
RY15
GND
RC-
RY13
RY14
RY15
RTH
RC+
12
AB
8 Stage
++
Battery ABattery B
--
2 Stage
Between RC+(pin10)
and RC-(pin9)
SW Open
SW Short
Charger
ON
OFF

6
A
BA
B
12
34
56
78
9 10
8 Stage 2 Stage
+
+
Battery A
Battery B
-
-
AWG
14 2.1 12
12 3.3 22
10 5.3 35
7 10 46
6 16 60
4 25 80
CROSS SECTION(mm ) Max. Current(A)
UL1015(600V 105 )
2
The temperature
sensor can either
be attached to the
battery or placed
in its surrounding
environment. NTC
Temperature sensor comes along with the charger can be connected to the unit to allow temperature compensation of the charging
voltage.
7.6
If the temperature sensor is not used, the charger still works normally.
Temperature Compensation
Select suitable wire gauge based on rated charging current. Refer to the following table for minimum wire gauge. We highly
recommend using RED wire for + connection and BLACK wire for - connection:
8.Wiring for battery
7.4 Charger OK Relay(RY15)
9
9
10
10
CN100
CN100
RY13
RY13
RY14
RY14
RY15
RY15
GND
GND
RC-
RC-
RY13
RY13
RY14
RY14
RY15
RY15
RTH
RTH
RC+
RC+
1
1
2
2
Normal work
Charger
Failure or the protection
function is activating
ON (Short)
Between pin5 and pin6
OFF(Open)
RY15
7.5 Output OK Relay(RY13 & RY14)
1.Bank A OK (RY13)
2.Bank B OK(RY14)
Bank A
Bank B
Color of LED A
Color of LED B
Battery A Full
Battery B Full
Charging
Charging
Between pin1 and pin2
Between pin3 and pin4
ON (Short)
ON (Short)
Green
Green
OFF(Open)
OFF(Open)
Orange
Orange RY14
RY13

7
11.Failure correction notes
If you are not able to clear the failure condition, please contact Mean Well or any of our distributors
for repair service.
WARNING : This is a class A product. In a domestic environment this product may cause radio interference in which case the user may
be required to take adequate measures.
Status
Unable to charge
the battery
LED indicator does
not turn Green after
a long charging
period
Possible Reasons
ON/OFF switch in the OFF position Switch to the ON position
Switch to the ON position
Use battery with the correct voltage
Make sure input source is between 90~264VAC
Replace with a new battery
Replace with suitable wire gauge
Battery reverse polarity
Battery with higher voltage is connected
Input AC voltage is too low
Battery exceed lifespan or damaged
Output cables are too thin
Ways to Eliminate
9.Suggested battery capacity
1.Batteries in series
Voltage can be doubled when 2 batteries are connected in series. However, the capacity (AH) will remain the same.
For example, 2 x 12V 100AH batteries connected in series = 24V 100AH.
10.Series and parallel connection of batteries
2.Batteries in parallel
When 2 batteries are connected in parallel, voltage remains the same and the capacity (AH) doubles.
For example, 2 x 12V 100AH batteries connected in parallel = 12V 200AH.
Note:1.Using battery capacity larger than the suggested value will not lead to damage of battery. The only drawback is it may take
longer to fully charge the battery.
2.If you're unsure about max allowable charging current of the battery, please refer to the battery's technical specification or
consult its manufacturer.
Model
PB-1000-12 200-600AH
PB-1000-24
PB-1000-48
120-350AH
60-175AH
Battery capacity
+
+
+
+
Battery
Battery
Battery
Battery
-
-
-
-