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.

--3--
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.

--4--
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.

--6--
Connection Plan for 12 V Operation:
Observe the polarity (+,-) of the battery!
First connect the charger (it is short circuit-proof), and after that the batteries (not short circuit-proof).
Observe the cable cross-sections and lengths of the battery, see table 1.
Safety Instructions: Mains connection is only allowed 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).

--7--
Connection Plan for 24 V Operation:
Observe the polarity (+,-) of the battery!
First connect the charger (it is short circuit-proof), and after that the batteries (not short circuit-proof).
Observe the cable cross-sections and lengths of the battery, see table 1.
Safety Instructions: Mains connection is only allowed 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).

--8--
Option: Second Charging Port "Starter Battery":
That charging port is provided for support charging or trickle charging of the vehicles' starter battery in case of
extended stop periods and for compensation of the charge for e. g. short-term consumers (interior lighting of the driver's
cabin etc.). The LED „ Battery Start “ is lighting.
The output voltage of this port is slightly lower than the output voltage of the main port „A“. Its current intensity is
limited to approx. 2 A, and it is quipped with a separate charging control. Thus, an overcharging of the vehicle's battery
can be absolutely excluded.
The second charging port with separate charging control may be used or not used, the function of the
main charging port „A“ will not be affected.
Option: Sensor Lines (Terminals „Sense“):
Particularly in case of powerful chargers being equipped with long charging cables, it is recommendable to measure the
battery voltage via a "sensor line" directly at the battery. This allows a more precise observation of the charging voltage
rates.
It is recommendable to install these sensor lines in case of charging cables, which are strongly deviating from the values
in table 1 (see connection plan).
Please observe for 24 V operation, that the „Sense“ line should be connected to the „+“ pole of that battery, where also
the „+“ charging cable of the charger will be connected.
Absolutely observe the connection plan!
If several batteries are connected in parallel to a battery system, the „Sense“ line has to be connected to one of the +
poles being connected to each other.
The charger will automatically recognize and evaluate the sensor line(s).
If the sensor line is not installed or in case of a cable break or fuse failures, it will be switched to normal
operation with charging cable compensation (calculated compensation of the voltage losses on the charging
cables).
Option: Remote Control (Tip Jack „Remote Control“)
If the charger has been installed at a difficultly accessible location, the Remote Control for
Automatic Charger SMT (Order No. 3129) can be used for remote control of the
charging process.
Connection:
Just insert the plug of the remote control into the tip jack "Remote Control" of the charger.
Functioning:
The remote control is equipped with the same pilot lamps (light-emitting diodes) as the
charger (except of the starter battery).
Switch Function (also refer to paragraph Switch „AC Power Limit“):
Position „ON“: The charger works with full charging capacity ("AC Power Limit" in position I) or with reduced
charging capacity ("AC Power Limit" in position II).
Position „OFF“: Ensures silent operation on board by means of the function “silent run “, noise optimised operation
(night operation):
The internal cooling fans of the unit will be set to constant low noise, steady speed.
All light-emitting diodes will be switched off, only the current display „Current“ will still be lighting weakly.
Of course, all charging and control functions continue working internally to the full extent
The reduced cooling capacity might reduce the charging capacity to approx. 70-50 %, depending on the
ambient temperature of the charger.
Manual reactivation of the display and thus of the full charging capacity:
is possible at any time by switch position "ON".
Automatic reactivation after 10 hours by integrated timer (end of nighttimes)
Further Switches and Miscellaneous Functions:
Mains Switch (Unit Rear):
The charger has to be switched off prior to connection of the batteries or other connection tasks (switch position „0”)!

--9--
Switch „AC Power Limit“:
This switch allows to reducing the capacity of the charger to be able to use it also, if the local 230 V mains only offers
smaller capacity rates (weak protection of the parking lot, country current supply or Marina, generator operation).
The reduced current consumption of the unit from the mains supply in case of switch position „II“ can be drawn from
the technical data below „Delimitation of Capacity / Switch „AC Power Limit“.
Switch position „max.“ = Normal operation, maximum input power and charging capacity
(factory adjustment)
Switch Position „II“ = Reduced power consumption of the unit from the mains supply.
(e. g. if the mains of the parking lot is protected weakly, serves for protection
of the mains fuse)
Switch Position „I“ = Silent Run Function, noise optimised operation (night operation)
(Internal fans of the unit will be set to constant low noise, steady speed, any light-
emitting diodes of the display will be switched off, only the current display will still be
lighting weakly, the charging capacity is reduced to approx. 50 %).

--10--
Indicator Lamps:
„Battery Full“ (Battery (Batteries) fully charged, green)):
If it is lighting: Battery (batteries) has (have) been charged to 100 %, trickle charge U2, finished.
If it is flashing: Main charging process in the charging phase U1 is in progress, charging state is
increasing from approx. 75 % to 100 %.
Off: Main charging process is still being executed in the phase I.
„Main Charging“ (Main charging, yellow):
If it is lighting: Main charging process is effected in the charging phase I or U1.
Off: Trickle charge U2.
If it is flashing: 1. Disconnection of the battery protection: battery “A” temperature <-40 ° C or temperature
rise (depending on type, e.g. 57 ° C or 63 ° C), automatic reset in case of slight cooling off,
or
2. External battery overvoltage > 15.50 V (> 31.0 V) after 20 seconds
automatic reset <12.75 V (<25.5 V) after 30 seconds
„Current“ (Charging Current, red):
The lighting intensity of the LED „Current“ (Charging Current) will be reduced or increased depending on the
supplied charging current.
„Power / Attention“ (Mains, red):
If it is lighting: Mains supply is available and charger is ready for operation.
If it is flashing: Disconnection of the safety timer, duration of the charging phase I was too long,
battery defective (short-circuit of the cells), too many consumers, switch „Cap“ has been set to a
value, which is too low. Reset is only possible by switching the mains switch to OFF.
Or internal unit failure (overheating), automatic reset after cooling down.
„Battery A“ (yellow):
If it is lighting: Main battery „A“ will be charged.
„Battery Start“ (yellow):
If it is lighting: Starter battery of the vehicle is charged.
Charging Process Main Battery „A“:
A new, complete main charging cycle will be executed:
After a power failure or disconnection by means of the mains switch (position „O“) the unit plug or mains plug
must be withdrawn.
In case of a lower deviation of the battery reset voltage of 12,75 V (25,50 V) beyond the maximum charger current
for 30 seconds due to high load.
1. Charging aid for totally discharged battery: From 1.0 V, preliminary gentle charging with a small current rate up
to 8 V (16 V).
2. Maximum charging current (Phase I) in the mean voltage range from 8 V (16 V) to the beginning of the phase
U1 for short charging times. The LED „Main Charging“ is lighting, and 75 -80 % of the capacity will be
charged. The duration of the phase I depends on the battery conditions, the floating load and the charging state.
The charger records the charging process and switches automatically to the next phase U1. If the duration of the
charging phase I was too long, the charger will be switched-off (safety timer against cell defects etc., the LED
„Power/Attention“ is flashing).
3. During the Phase U1 (LED „Main Charging“ is lighting) the battery voltage will be kept constantly on a high
level. The green LED „Battery Full“ is flashing, and the additional high
battery capacity over 80 % will be charged. The battery charging current is decreased slowly while full charging
is increasing. The charger controls the charging time as well as the charging current. From these values and from
the course of charging being recorded during the phase I, the charger determines the 100 % full charge point of
the battery for automatic commutation to U2.
In contrast to conventional chargers with fixed default values for charging current commutation, an unnecessary
long phase U1 is avoided, which might be caused by floating loads being eventually also supplied, and which are
falsifying the charging current.
„Main Charging“ will stop lighting.
4. Phase U2 ( „Battery Full“ is lighting permanently, 100 %): The charger has now switched to the lower
voltage for trickle charge maintaining 100 % charge of the battery. Only the low compensating recharging
current is flowing, which is determined by the battery, and which is required for constant conservation of the full
charge.
5. Battery Regeneration: To ensure a circulation of acid accumulation in case of extended periods of trickle
charge (due to e. g. stop periods of the vehicle), the charging voltage rate will be raised automatically to U1
twice a week for one hour. After that, direct return to U2.
Note: During the phases U1, U2 (Battery Full) almost the total charger current is available
for additional supply of consumers without any discharge of the battery.