Votronic Pb 1280 SMT 2B User manual

Installation and Operating Manual
Automatic Charger Pb 1280 SMT 2B Charging Capacity 12 V / 80 A No. 3131
Automatic Charger Pb 2440 SMT 2B Charging Capacity 24 V / 40 A No. 6250
Please read the mounting instructions and operating manual including the safety
regulations completely prior to starting connection and start-up.
If not connected to the battery the units will not supply any voltage (protection against
wrong polarization, safety relay, minimum battery voltage 1.0 V)!
NOTE: The values being indicated in parentheses ( ) apply to 24 V operation.
All-automatic battery charger with 2 charging ports for intervention vehicles, special-purpose
vehicles, special high-quality campers, as well as marine application.
VOTRONIC chargers of series “PB SMT” are of compact design and have only a low weight (high frequency switching
power supply, switch mode technology). They distinguish by full charging capacity, even in case of large deviations of
the power supply (low voltage/overvoltage, sine curve, frequency).
The intelligent microprocessor charging control with characteristic lines of charging „IU1oU2“ and dynamic calculation
of the charging time automatically ensures quick and careful full charging followed by 100 % trickle charging of the
connected batteries from any charging state, allowing always simultaneous supply of 12 V (24 V) consumers being
connected in parallel or charging of very large batteries (depending on the case of application).
Battery Ports and Charging Programs:
Main charging port “A”, depending on the type of battery, 3 charging programs selectable (see table 3):
a) AGM“: Closed, gas-tight AGM/fleece batteries VRLA (lead-fleece technology) “14.8 V”
b) „Gel“: Closed, gas-tight Gel/dryfit batteries VRLA (determined electrolyte)
c) „Lead Acid“: Closed and open acid/lead-acid batteries, as well as AGM with indication of the
charging voltage "14.4 V"
2. Charging Port Battery "Start":
For support charging and trickle charging of the vehicle's starter battery with separate charging control.
Operating Instructions:
The charging voltage being free from peaks is controlled in such a way, that any overcharging of the batteries
is excluded.
All-automatic Continuous Operation: The charger may be connected continuously to the batteries, thus keeping
the full charge. Battery discharge in case of power failure is avoided (safety relay).
Silent Run Function: Noise-optimised operation (night operation).
Battery regeneration in case of extended stop periods: automatically twice a week to avoid harmful acid
accumulation.
Parallel and Floating Operation: In case of simultaneous consumption, charging of the battery is continued, or
the charge will be conserved fully. Calculation and control of the adaptation of the charging time is effected
automatically by the charger. Sensitive consumers are protected by overvoltage protection at any charging state.
Unattended Charging: Multiple protection against overload, overheating, overvoltage, short circuit, reverse
battery, excess temperature of the battery, incorrect behaviour and back discharge of battery by electronically
controlled gradual reduction down to complete separation of charger and battery by integrated safety relays.
Charging Cable Compensation: Automatic compensation of voltage loss on the charging cables. Measurement
of the voltage is to be effected at the battery and never at the charger (loss at the charging cable).
Charging aid for totally discharged batteries: Gentle preliminary charging of the battery to 8 V (16 V), followed
by powerful support of the battery, if consumers should still be switched-on.
Integrated On-board Mains Suppression Filter: Unproblematic parallel operation of solar systems, dynamos,
generators etc.
Temperature Compensation: The external temperature sensors effect an automatic adaptation of the charging
voltage rates to the battery temperature. In case of low outside temperatures, full charging of the weaker battery
is improved, and in case of summery temperatures unnecessary battery gassing will be avoided. This is highly
recommended, if the battery is exposed to strong variations in temperature, e. g. in the motor compartment.

--2--
Interruption or restart of the charging process:
Due to power failure or unit switch OFF.
In case of frequent interruptions, particularly before reaching the full charge ("Battery Full" is lighting
permanently), a complete charging cycle of 24 hours of the battery should be executed more often
(compensation charging).
Lifetime of the battery:
Keep batteries cool; choose an appropriate location for installation.
Open acid batteries („maintenance-free according to EN / DIN“): Check the acid level
periodically!
Batteries being totally discharged should be recharged immediately, partially discharged
batteries should be recharged fully as soon as possible to avoid sulphation!
Store only fully charged batteries and recharge them periodically, particularly in case of older,
used batteries and in case of higher temperatures! If the grade of sulphation is not too intensive, the
battery can recover part of the battery capacity after several charging/discharging cycles.
Safety Regulations:
Appropriate Application:
The battery charger has been designed according to the valid safety regulations.
Appropriate application is restricted to:
1. Charging of lead-acid, lead-gel or lead-AGM batteries of the indicated nominal voltage and the
supply of the consumers being connected to these batteries in fixed installed systems with the
indicated battery capacities and charging programs.
2. Connection to a shock-proof socket, which has been installed according to the valid technical
regulations, protected with max. 16 A (if required mobile/stationary with a fault current breaker
(FI) with a nominal residual current of 30 mA).
3. Connection in consideration of the indicated cable cross sections at the charger ports.
4. Fuses of the indicated capacity are to be provided near the battery to protect the cabling between
battery and charger port.
5. Technically faultless condition.
6. Installation in a well-ventilated room, protected from rain, humidity, dust, aggressive battery gas, as
well as in an environment being free from condensation water.
Never use the unit at locations where the risk of gas or dust explosion exists!
Open-air operation of the unit is not allowed.
Lay the cables in a way, that damage is avoided and observe to fasten them tightly.
Never lay 12 V (24 V) cables and 230 V mains supply cables into the same cable conduit (empty conduit).
Check live cables or leads periodically for insulation faults, points of break or loosened connections. Occurring
defects must be remedied immediately.
The unit is to be disconnected from any connection prior to execution of electrically welding or work on the
electric system.
If the non-commercial end-user is not able to recognize the characteristic values being valid for a unit or the
regulations to be observed, a specialist is always to be consulted.
The user/buyer is obliged to observe any construction and safety regulations.
The unit does not contain any parts, which can be replaced by the user. Even after withdrawal of the
mains plug, the unit may be extremely live for an extended period (particularly in case of failure).
Keep children away from the charger and the batteries.
Observe the safety regulations of the battery manufacturer; deaerate the battery room.
Non-observance may result in injury or material damage.
The warranty period is 24 months from the purchase date (against presentation of the sales slip or invoice).
The warranty will be void in case of any inappropriate utilisation of the unit, if it is used beyond the technical
specification, in case of improper operation or external intervention. We do not assume any liability for any
damage resulting hereof. The liability exclusion is extended to any service being executed by third, which has
not been ordered by us in writing. Service is to be effected exclusively by VOTRONIC, Lauterbach.

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Installation of the Unit:
Install the charger near the batteries “A” (short charging cables) at a clean, even and hard mounting surface, which is
protected from moisture and humidity.
The unit can be installed in any position. Protect the unit from aggressive battery gases.
Despite the charger's high efficiency, heat is produced, which is brought out of the casing by means of the built-in fan.
The vent holes of the unit should never be covered (minimum distance 10 cm) to ensure full charging capacity. Ensure
sufficient ventilation in the environment of the unit so that the heat can be carried-off.
Otherwise, the unit might effect a slight reduction of the charging capacity in case of increased heating.
Solid and vibration reducing installation by means of the rubber feet. Never remove these rubber feet!
Start-up: Initial Battery Connections and Settings:
Observe the connection plan 12 V or 24 V, as well as table 1 indicating the cables and +fuses!
1. Connect the battery (batteries) to the terminals „ Com- “ and „ A+ “ observing the correct polarity
2. Connect the supplied temperature sensor to the terminals „ T T “ of battery „ A “ (see page 5).
3. Set the switch „ AC Power Limit “ to position „ max. “.
4. Set the battery size (capacity, Ah): See table 2.
5. Set the charging program for the battery type (design): See table 3.
Insert the mains plug and position the mains switch (unit rear) to position „I“. The all-automatic charging process
starts.
Table 1: Recommended lengths of charging cables, cable cross sections and +fuse capacities:
Lengths of charging
cables -Com and
+A
Pb 1280
Pb 2440
2x 1.0 -2.0 m
16 mm2
10 mm2
2x 1.5 -3.0 m
16 mm2 * *
10 mm2 * *
+Fuse
100 A
50 A
* * = It is recommendable to use the sensor line (terminal „Sense“, see option sensor lines).
Table 2: How to set the battery size „A“ (capacity, Ah) using the switch „Cap.“:
Battery
Capacity
Selector
Switch
„Cap.“
Pb 1280
Pb 2440
Charging
Phase I
Safety Timer
max.:
h
Battery
Capacity
Ah
Charg-
ing
Current
A
Battery
Capacity
Ah
Charg-
ing
Current
A
150-180
60
75-92
33
5,2
180-380
80
92-140
40
7
380-560
80
140-250
40
10
560-880
80
250-480
40
15
Note: If 2 or several batteries are connected to the charging port „A“, set the total capacity (total Ah)!
In case of high additional current consumption by connected consumers, the switch „Cap.“ can also
be set by 1 step higher.

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Table 3: How to set the battery type „A“ (design) using the switch „Type“ (charging
program):
Selector
Switch
„Gel-
AGM“
If not being specified divergently by the battery manufacturer, the suitable charging program
for the battery type (design, technology) can be determined by means of the following
description and the technical data (voltage rates U1 and U2, nominal temperature and dwell
times U1).
Note: The possible parallel/floating operation with consumers being connected to the battery
(batteries) is also automatically considered by all charging programs.
„ Lead Acid “: Universal charging program for lead, acid/lead-acid batteries:
For charging and trickle charge of supply (board) batteries. Ensures short charging times, high
charging factor and acid mixing for open standard batteries and closed, low-maintenance,
maintenance-free "non-solid electrolyte", "lead-acid", drive, lighting, solar and heavy duty batteries.
Also suitable for recently developed batteries (low-antimonous, batteries with silver-alloy,
calcium/calcium or similar) and batteries with low and very low water consumption,
as well as AGM batteries with charging voltage indication "14.4 V".
Universal Characteristic Line IU1oU2oU3:
U1 Main/Full Charging: 14.30 V (28.6 V) 25 °C 2.5-6 h
U2 Full/Compensation Charging: 13.85 V (27.7 V) 25 °C 2 h
U3 Full/Trickle/Storage Charging: 13.40 V (26.8 V) 25 °C Continuous
„ AGM “: Charging Program for Lead, AGM / Fleece Batteries:
Adapted to closed, gas-tight AGM (absorbed glass mat) batteries and batteries in lead-fleece
technology requiring a particularly high level U1 for full charging.
ATTENTION: It is highly recommended to check the specification sheet of the battery concerning
the high charging voltage U1 14.7 V.
Unsuitable batteries might age prematurely due to loss of electrolyte!
Some manufacturers of AGM/fleece batteries are also prescribing a "gel" or "acid" charging program
for charging!
In these cases, please set "Lead Acid (14.3 V / 13.4 V).
Characteristic Line AGM- / Fleece IU1oU2:
U1 Main/Full Charging: 14.70 V !! (29.4 V) !! 20 °C 3-6 h
U2 Full/Trickle/Storage Charging: 13.50 V (27.0 V) 20 °C Continuous
„ Gel “: Charging Program for Gel/Dryfit Batteries:
Adapted to closed, gas-tight Gel batteries with determined electrolytes, which are generally requiring
a higher charging voltage level and longer dwell times U1 to achieve short charging times with
particularly high capacity storage and to avoid total discharge, e. g. EXIDE, Sonnenschein dryfit-
Start, Dryfit-Sport-Line, DETA Gel Battery Funline, Bosch AS Gel Batteries Va/Z, AS Gel Drive
Batteries, AS Gel Lighting Batteries.
If not being specified divergently by the battery manufacturer, also recommended for batteries in
round cell technology, such as EXIDE MAXXIMA (DC).
EXIDE, DETA, VARTA Characteristic Line Gel IU1oU2:
U1 Main/Full Charging: 14.40 V (28.8 V) 20 °C 8-12 h
U2 Full/Trickle/Storage Charging: 13.80 V (27.6 V) 20 °C Continuous
Not used (operates like the gel program)

--5--
Temperature Sensors (Terminals „T T“ Battery „A“):
The temperature sensor (Order No. 2001) controls the battery temperature and the temperature-dependent correction
of the charging voltage. (Characteristic lines, see also "Temperature Compensation" in this manual).
Connect the sensor to the corresponding terminals „T T“ of the unit (any polarity).
Sensor Installation:
The thermal contact of sensor and battery (inside temperature) should be well. Thus, it should be screwed down to
the negative pole of the battery. It is also possible to fasten it at the sidewall centre of the battery casing. Ensure that the
installation place is not influenced by any source of heat (motor unit, exhaust, heater etc.).
Temperature Compensation:
The temperature-dependent charging voltage of the battery will be adapted automatically to the battery
temperature.
The temperature sensor measures the battery temperature. In case of low temperatures (winter operation), the charging
voltage will be increased in order to improve and accelerate full charging of the weak battery. Sensitive consumers are
protected by a limitation of the voltage in case of very low outside temperatures.
In case of summery temperatures, the charging voltage is reduced to minimize the load (gassing) of the battery and to
extend the lifetime of gas-tight batteries.
Battery Protection (see Characteristic Lines "charging voltage and temperature compensation"):
At high temperatures of the battery (depending on type, for example 54 ° C or 58 ° C) the charging current
will be reduced to 50 % as a precaution. If the temperature of the battery rises still further, few ° C higher a
complete disconnection is issued by the safety switch. LED "Main Charging" will be flashing. All
previous data of charging will be recorded. The automatic charging will continued if the temperatures is
fallen below the above temperatures. The charging process is also blocked at battery temperatures
below –40 ° C.
The charger recognizes automatically a missing sensor, cable break or short-circuit of the sensor lines, as
well as unreasonable measuring values. In that case, it will switch to the usual nominal voltage rates of
20 °C / 25 °C being recommended by the battery manufacturers.
Further Switching Types and Options:
Note: Several batteries (battery bank) at the charging port „A“:
According to the battery manufacturer, permanent parallel operation is admissible in case of two or several batteries of
the same voltage, type, capacity, as well as of the same age (history) in cross connection.
The total capacity (Total Ah) should not exceed the indicated maximum battery capacity, and it is to be set
correspondingly using the selector switch „Cap.“!
The batteries are to be „paralleled“, i. e. the „+“ connections of the batteries are to be coupled, and they are to be
connected to the „+“ connection of the charger.
. The minus (-) connections have to be coupled in the same way.