PB-600 Instruction Manual
Contents
1. E Battery Battery 11 Recommended wire specification Installation Safety rating Maximum length Desktop counter top chassis box mobile SP 2 SPE 2 SPT 2 SV SVE SVT 10ft 3 meter Grounded fixed in place not mobile S SE SO SP 3 SPT 3 ST STO SJ SJE SJO SJT SJTO Not specified Note Please install in accordance with the table above Wire gauge should be no smaller than No 18 AWG 3C Socket type restricted to 15A 125V NEMA 5 15P or 15A 250V NEMA 6 15P with power cord length ranging from 1 8 meters to 10 meters 12 Failure correction notes the battery connected Status Possible reasons Solutions ON OFF switch in the OFF position Switch to the ON position Battery reverse polarity Reconnect using the right polarity Unable to charge Battery with higher voltage is Use battery with the correct voltage Input AC voltage is too low Make sure input source is between 90 264VAC LED indicator does not turn damaged Green after a Battery exceeded lifespan or Replace with a new battery long charging period Output cables are too thin Replace with suitable wire gauge If you are not able to clear the failure condition please contact Mean Well or any of our distributors for repair service BH amp 4 Se Bg 3 A DR MEAN WELL ENTERPRISES C2. PB 600 Instruction Manual MW MEAN WELL PB 600 Instruction Manual Index 0 Product descripBlOf oss dementen 1 Notes on operation 2 Front and back panel 3 Derating CUIVE 3 1 Charging current VS 3 2 Charging current VS 4 Function description for CN100 csse 5L EB IndicatlOh sean Rn teheran eneen sena ine EDI 6 Explanation of operation logic charging stages 6 1 2 stage charging flick switch to 2 stage 6 2 stage charging flick switch to 6 3 8 stage charging flick switch to 8 7 Function description 7 1 Input voltage 7 4 2 3 or 8 stage charging mode selection 7 5 Reverse polarity protection ns anan ennen eer enen vereen nee 6 Fan speed Control eese i enerverende vanden eren armen erh 7 7 Charger OK relay RY15 sss eene 7 8 Output OK relay RY nnda robe ded 7 9 Temperature compensation ereen es 8 Wiring for battery iei 9 Suggested battery capacity
3. sss 10 Series and parallel connection of batteries 11 Recommended wire specification 12 Failure Correction NOTES en Aug 2013 Version 10 0 Product description PB 600 is MW s next generation smart charger It has many of the protective features that consumers would like tohave ina charger including battery misconnection wrong voltage reverse polarity battery disconnection or not connected and battery failure analysis The latest high efficiency switching topology plus microcontroller power management are utilized in its design Three types of charging curves are offered for lead acid battery charging 2 stages for quick charging 3 stages quick float and 8 stages for optimized charging Charging stage selection can be easily made by the userthroughthe selection switch on the front panel Depending on battery brand and type lead acid gel lithium iron and lithium manganese the battery may require special charging curves and adjustment tothe protective functions which differs from the standard settings The charging curves and protective functions can be customized by reprogramming its firmware Basically you can change the voltage current settings of each individual stage plus adjust or cancel the protective functions Please note the factory charging curve is for charging lead acid battery Pl
4. T MONETE TII Charge Current BM 10 T T stage stage2 stage 3 Constant Current Constant Voltage Battery Full Color of LED Orange Green State PB 600 12 PB 600 24 PB 600 48 Constant 40A 21A 10 5A Current Vboost 14 4V 28 8V 57 6V Vfloat 13 8V 27 6V 55 2V Figure 6 2 3 stage charging curve Explanation for 3 stages charging curve 0 Initial stage battery analysis Check battery voltage level to see if it is within the normal range whether or not a battery is connected or if the battery is already full and further charging is not required 1 Stage 1 constant current A constant current is provided so the battery can be quickly charged to 2 4V per cell 2 Stage 2 constant voltage A constant voltage of 2 4V per cell is provided until the charging current naturally tapers down to 1096 then moveon to stage 3 3 Stage 3 Float voltage A float voltage of 2 3V per cell is provided so that the battery can maintain full charge Forapplications that utilize the charger PB 600 to charge batteries and supply system power simultaneously e g UPS system please select 3 stage charging for the best use of the charger 6 3 8 stage charging flick switch to 8 stage 8 stage charging provides optimized charge to lead acid battery It also prolongs battery life and increase storage capacity Some ofthe main advantages are as below Advantage of pulse stage Use pulse cur
5. Vboost 1 T Charge Voltage r 100 Charge Current anniek 10 i stage1 stage2 Constant Current Constant Voltage Battery Full ColorofLED Orange Green State PB 600 12 PB 600 24 PB 600 48 Constant Current 40A 21A 10 5A Vboost 14 4V 28 8V 57 6V Figure 6 1 2 stage charging curve Explanation for 2 stages charging curve 0 Initial stage battery analysis Check battery voltage level to see if it is within the normal range whether or not a battery is connected or if the battery is already full and further charging is not required 1 Stage 1 constant current A constant current is provided so the battery can be quickly charged to 2 4V per cell 2 Stage 2 constant voltage Aconstant voltage of 2 4V per cell is provided until the charging current naturally tapers down to 10 then stop charging 6 2 3stage charging flick switch to 3 stage 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 programmed to last no longer than 24hrs When charging current decrease to less than 1096 of max LED indicator will turn Green to show a full charge The charger will now maintain a float charge voltage stage 3 Start j EN Vboost Vfloat Charge Voltage 1
6. beattachedtothe Battery battery or placed in its surrounding environment 8 Wiring for battery Select suitable wire guage based on rated charging current Referto the following table for minimum wire gauge We highly recommend using RED wire for connection and BLACK wire for connection P Max Current A AWG CROSS SECTION mm UL1015 600V 105 C 14 2 1 12 12 3 3 22 10 5 3 35 7 10 46 6 16 60 4 25 80 9 Suggested battery capacity Model Battery capacity PB 600 12 135 400AH PB 600 24 70 210AH PB 600 48 35 105AH Note 1 Using battery capacity larger than the suggested value will not lead to damage of the battery The main drawback is it may take longer to fully charge the battery 2 If you re unsure about max allowable charging current of your battery please refer to the battery s technical specification or consultits manufacturer 10 Series and parallel connection of batteries 1 Batteries in series Voltage can be doubled when2 batteries areconnected in series However the capacity Ah will remain the same For example 2 x 12V 100Ah batteries connected in series 24V 100Ah Battery Battery 2 Batteries in parallel When 2 batteries are connectedin parallel voltageremainsthesame and the capacity Ah doubles For example 2x 12V 100Ah batteries connected in parallel 12V 200Ah
7. The charger should be turned OFF prior to battery connection Suitable wire gauge should be chosen based on rated charging current of the charger 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 plugging in the AC power cable flick the ON OFF 0 switch to the ON position The LED indicator on the switch will light up 3 Derating curve 3 1 Charging current VS temperature 3 2 Charging current VS input voltage LOAD LOAD i 20 10 20 30 40 50 60 70 HORIZONTAL 90 95 100 115 L dU AMBIENT TEMPERATURE C INPUT VOLTAGE VAC 60Hz 4 Function description for CN100 Pin No Function Description Relay contact rating max 30V 1A Short when battery is full 12 FORES Open when battery is still charging Pin No Function Description Relay contact rating max 30V 1A Short when the unitis working 5 6 IER properly Open when theunit has failed or protection has activated Temperature sensor which comes with the charger can be connected to the unitto allow temperature compensation ofthe charging voltage If the temperature sensor is not used the charger can still work normally 7 8 G
8. ND RTH Turn the output ON and OFF by electrical or dry contact between 0 Bean pin10 RC and pin9 RC Open start charging Short stop charging 5 LED Indication Color Status Steady Flashing Red Fail Orange Charging Green Full Charging Types of failure 1 Battery disconnected 2 Damaged battery 3 Reverse polarity 4 Incorrect battery voltage e g PB 600 12 connected to 24V battery 6 Activation of protection function e g OTP OVP and Short 6 Explanation of operation logic charging stages PB 600 has atotal of 3 charging modes to choose from 2 stages 3 stages and 8 stages 8 stages charging differ from 2 stages with the addition of pulse soft start analysis recondition float and maintain stages 2 stages provide simple and quick charging 3 stages is similar to 2 stages with the exception of not shutting OFF after the battery is fully charged Lastly 8 stages will allow charging to maximum capacity Usercan select between 2 3 or 8 stages depending on their requirement 6 1 2 stage charging flick switch to 2 stage 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 to show a full charge and the charger will turn OFF
9. O LTD 248 A dt rb E RE A B K 28 5 No 28 Wuquan 3rd Rd Wugu Dist New Taipei City 248 Taiwan Tel 886 2 2299 6100 Fax 886 2 2299 6200 http www meanwell com E mail info meanwell com Your Reliable Power Partner
10. ating will be required when input voltage is below 100Vac 7 2 PFC Built in active PFC circuit PF gt 0 95 when input voltage is between 90 230Vac with full load atthe output On the other hand if the input voltage is gt 230V or outputis not atfull load the PF will drop below 0 95 7 3 Remote control The charger can be turned ON OFF by using the remote control function Between Rt pin10 Charger andRC pin9 SW open ON SW closed OFF gt OROROROKO z z H O id 8 3 2 ZOO Q II Q II amata 5 CHO Battery 7 4 2 3 or 8 stage charging mode selection The charger features user selectable 2 3 or8 stage charging The charging CN100 1 RY13 RY13 NC NC RY15 RY15 GND RTH m RC RC profile is selected by moving the slide switch on the back panel Switch Charging mode Slide right 2 stage charging bac SOES m Q IR Middle 3 stage charging es Bal Q OLS Slide left 8 stage charging H E OHS Q COO Stage 8 3 2 F Battery 7 5 Reverse polarity protection With built in battery reverse p
11. ease contact MW regarding other types of battery charging requirements Notes on operation Designed for charging lead acid battery Must be installed in a dry and well ventilated area It should not be exposed to rain or snow OThe cables between charger and battery should be keptas shortas possibleto prevent excessive voltage drop Too much voltage drop will lead to longer charging period OPlease make sure charging voltage and current meets battery specification Refrain from connecting new and old batteries in series Charger should be in the OFF mode before making battery connection or disconnection OThree years warranty is provided under normal operating conditions Failure resulting from improper operation will result in cancellation of warranty 2 Front and back panel ACINLET ON OFF SWITCH ON orF Ventilation Hole Figure 2 1 Front Panel Battery Common Positive Negative Gorda sy LED in jog MOTE ROBE OR Indicator ere o e OS L m Q 9 9 9 213 18 stage selection switch Function Connector OOOQO 2 L e oaf AN WARNING Battery Please check battery polarity before Figure 2 2 Back Panel connection Assembly guidelines 1
12. olarity detection circuit When the battery is connected in reverse at the output terminal of the charger the output relay circuit will remain open 7 6 Fan speed control With built in fan speed control circuit the fan will automatically change speed depending on load condition CN100 7 7 Charger OK relay RY15 1 RY13 RY13 2 Charger Between pin5 and pin6 NC NC Working normally ON short 15 RY15 Failure or RISSE Son OFF open GND RTH function has activated 9 RC RC M0 RY15 o 7 8 Output OK relay RY13 CN100 1 2 Battery Between pin1 andpin2 Color of LED NC NC Battery full ON short Green RY15 RY15 Charging OF F open Orange GND RTH 9 RC RC 10 7 9 Temperature compensation Temperature sensor which comes with the charger can be connected to the unit to allow temperature compensation of the charging voltage If the temperature 90 RY13 0 sensor is not used the charger can still work normally OI NONO NO NOI NO bomer OC QR IO HO ONO Stage 8 3 2 e I O L SOHO Q SSS Q OORO E Q AR Isl AN pe OL The temperature sensor can either
13. rentto revive aged battery Advantage of recondition 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 Pulse Soft Constant Constant Battery Recon Float sian Charge Start Current Voltage Analysis dition Charge Maintain Pulse Soft Constant Constant Analysis Recond Float Maintain Current Voltage 1 E I i E H 1 1 1 1 1 1 1 1 I 1 N T 1 I I Charge Voltage Charge Current d i stage 1 i stage 2 i stage 3 i stage 4 i stage 5 i stage 6 i stage 7 i stage 8 Color of Orange Green LED Figure 6 3 8 stage charging curve Explanation for 8 stages charging curve 0 Initial stage battery analysis Check battery voltage level to see if itis within the normal range whether or not a battery is connected or if the battery is already full and further charging is not required 1 Stage 1 pulse charging Pulse charging is usedto revive tired lead acid battery which is either improperly charged discharged or allowed to self discharge as occurs during non use Basically help to restore its normal chemical properties 2 Stage 2 soft start Use low cha
14. rge voltage and current to preparethe battery to acceptupcoming bulk charging so a better charge can be applied 3 Stage 3 constant current Ahigh constant current is provided so the battery can be quickly charged to 2 4V per cell 4 Stage 4 constant voltage A constant voltage of 2 4V per cell is provided until the charging current naturally tapers down to a low level 5 Stage 5 analysis The charger will stop charging for 2 minutes to determine battery status If the battery voltageis higher than 2 1V per cell the battery is determined as OK and will move on to stage 6 If the battery voltage is lower than 2 1V per cell the battery fail indication will come ON and the charger will stop charging 6 Stage 6 recondition boost charge Boost voltage is provided to recondition the battery storage capacity to its original state 7 Stage 7 float charge Afloat voltage of 2 3V per cell is provided for extended period of time about one day so that the battery can maintain full charge 8 Stage 8 maintain Maintenance charge is provided to compensate for battery self discharge and extend battery life 7 Function description 7 1 Input voltage Olnput voltage range is 90 264Vac or 127 370V dc The provided input voltage must fall within the specified range otherwise the unit may be non functional also the active PFC circuit may fail or get damaged OEfficiency will get lower when input voltage is atlow line Please note load der
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