Alternator-to-Battery Chargers ...

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AB1290
AB12160
AB12210
AB2460
AB24100
ABRC
S
TERLING
POWER PRODUCTS
Alternator-to-Battery Chargers
and Remote Control
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D
4
technology
RoHS
www.sterling-power.com
compliant
ProDigital
A
LTERNATOR
-
TO
-B
ATTERY
C
HARGER
I
NSTRUCTIONS
Safety Instructions
The output marked “domestic battery” comprises an intelligent,
software-controlled boost function which charges the domestic
Before connecting and running your Sterling alternator-to-
battery bank up to five times faster and much more efficient than a
battery charger, read the complete instructions and all
standard alternator could do. In addition, the batteries will take in up
cautionary labels on the unit and on the batteries. Only a
to 50% more charge current, allowing you to utilise their full capacity.
correct installation according to these instructions will let
While the alternator-to-battery charger greatly improves the charging
you take full advantage of your alternator-to-battery
of the domestic battery bank, the starter battery has always priority,
charger.
ensuring that the engine can be started at any time. Under no
circumstances will the system allow the starter battery to drop below
13V.
General Precautions
Always install the unit in a dry, cool and well-ventilated place.
Additional functions protect your electrical system and your batteries
Any contact with water and heavy humidity has to be avoided.
from possible faults such as overcharging or overtemperature. Any
Do not cover the fans to prevent the unit from overheating.
fault on the system will be indicated by a number of LEDs or on the
optional remote control unit.
Make sure all cables have the appropriate size and are in good
condition. Do not run the unit with cables that are damaged or
How it works
otherwise inappropriate.
In order to maximise the alternator output current, the alternator-to-
battery charger pulls the alternator output voltage down to about
13V. Then this low voltage is amplified to a higher voltage suitable
Precautions against Gas Explosions
The alternator-to-battery charger contains electrical
for effective battery charging, i.e. 14.1V to 14.8V. The unit’s
components which may produce sparks. In order to avoid the
intelligent software automatically calculates the optimum charge
risk of fire or explosion, do not install the unit in rooms
cycle and absorption time. When the batteries have been fully
containing batteries or highly inflammable materials or in any
charged, the voltage is reduced to float voltage (appr. 13.5V to
place requiring explosion-proof equipment. This includes any
13.8V).
room with petrol, gas or diesel driven engines or with tanks or
piping used for any such substance.
Before starting to install the charger please ensure that there is
Product Characteristics
sufficient ventilation. In order to prevent the formation of
explosive gases make sure that the batteries have not been
Easy installation:
It could not be easier. For the basic system only
charged for at least 4 hours prior to installation.
4 connections are required: one from the alternator(s), one to each
battery bank and one to the common negative. Apart from the
additional negative connection most of these cables will be on board
anyway.
Precautions when Handling Batteries
Someone should be within earshot, i.e. close enough to come
to your aid when working near a lead-acid battery. Have plenty
Advanced charging technology:
Intelligent, software-controlled,
of water and soap nearby in case battery acid comes in
4step charging of the domestic battery including temperature
contact with skin, clothes or eyes. Wear complete eye
compensation.
protection and protective clothing. Avoid touching the eyes
No interference with engine electronics:
Because the system
while working with a battery.
does not increase the voltage of the starter battery there is no risk of
If battery acid contacts skin or clothing, wash immediately with
problems with the electronic engine management system.
soap and water. If acid enters the eye(s), flood eye(s) with
running cold water for at least 10 minutes and seek medical
No work on the alternator required:
Absolutely no changes to the
attention immediately.
Never smoke or allow a spark or flame in the vicinity of a
alternator are required. As a result no warranty conflicts can arise.
Suitable for multiple alternators:
Unlike other systems the
battery or the engine.
alternator-to-battery charger can be used simultaneously on more
than one alternator, saving even more installation work and money.
Work with extra caution to reduce the risk of dropping a metal
tool onto a battery. It may create sparks or short-circuit the
Starter battery priority:
The system ensures that the starter battery
battery or other electrical parts that may cause an explosion.
is always kept in operational condition.
Remove all personal metal items such as rings, bracelets,
Intelligent fault protection:
The unit comprises multiple safety
necklaces, watches and jewellery when working near a battery.
features and fault indicators. Even in the unlikely event of a
A battery can produce a short-circuit current high enough to
complete failure, the unit will still work as a split charge diode.
weld a ring or any other metal which will lead to serious burns.
Enhanced installation options:
The unit comes with temperature
Never charge a frozen battery.
sensors for the battery and the alternator. It can be enhanced by an
optional remote control.
General Overview
Basic Installation
The Sterling alternator-to-battery charger is a fully automatic,
electronic multi-stage split-charge system which charges two
banks of batteries from one or more alternators. It combines an
advanced split charge diode system with a powerful voltage
amplifier. The unit has one input to connect to one or more
alternators and two outputs to charge two different battery
banks.
Important: These guidelines refer to the connections that have
to be made for the correct installation of the Sterling Alternator-
to-Battery Charger. On an existing system you may also be
required to remove some of the connections that were used to
charge the batteries prior to the installation of the unit.
Install the unit in a cool and well-ventilated position close to the
The output marked “starter battery” is a straight channel
alternator(s). Also, the installation point has to be dry and free from
through a diode; this is the channel that is connected to the
heavy condensation since the unit is not waterproof. Do not fit it in a
boat / vehicle engine system. In order to avoid any conflicts
closed box as this might lead to overheating of the unit and reduced
with an electronic engine management system, there is no
performance.
boost function on this channel.
The unit has three temperature-controlled fans. Therefore they will
2
run more often when the unit is installed in a place with a high
first two seconds of having the ignition key fully turned. During
ambient temperature.
these two seconds, a 12 volt feed is sent to the alternator B+
terminal which is enough to let the alternator fire up. Thereafter,
Before connecting the unit to your alternator(s) make sure that
the alternator looks after itself. Use a 0.5mm² wire for this
your alternator-to-battery charger ist rated for the maximum
connection.
output of the alternator(s).
Connect the main alternator output(s) (B+) to the centre stud
Multiple Alternators:
The alternator-to-battery charger can be
marked “ALTERNATOR INPUT. Then simply connect the other
used on more than one alternator at the same time. Simply
studs to the engine battery and to the domestic battery,
connect all alternator outputs (B+) to the alternator input terminal
respectively. Make sure that the cables used can carry the full
on the unit. Make sure that your alternator-to-battery charger is
current of the alternator(s). Choose a cable size that can carry at
rated for the combined maximum output of the alternators.
least twice as much current than required. For example, if you
have a 70A alternator, then use a 140A cable.
Remote Control:
(5)
The remote control kit is an optional extra
If you are only going to charge one bank of batteries, then use the
including a remote display and two 200A shunts. The two shunts
“DOMESTIC BATTERY” output only. The “START BATTERY”
measure the current coming from the alternator
(9)
and the
output can remain unused without affecting the performance of
current going into the starter battery
(8)
. From these values the
the unit.
electronics will calculate the current going into the domestic
battery.
The unit has a short negative wire which has to be extended and
connected directly to the alternator negative (or case) using a 60A
The remote control will keep you informed about voltages,
cable.
currents, temperatures and other operating figures. In the event
If you currently have a split charge diode, then the three positive
of a problem, it indicates what the problem is.
wires are already there. Simply replace the split charge diode with
the alternator-to-battery charger and connect the negative wire to
the alternator.
Battery Type Selection
Important:
If your alternator has got its own battery voltage sense
Programme the type of your domestic battery into the unit by
wire, then this has to be removed from the battery terminal and
using the dip switches
(6)
. The unit has four different battery type
should be connected to the alternator’s own B+ output instead.
settings:
This will prevent contradictory regulation between the alternator
Non-sealed lead-acid batteries
(where you can unscrew the lid
and the alternator-to-battery charger.
of the battery and top it up with water): The absorption voltage is
14.8V.
Extended Installation
For additional functions and improved performance some extra
features can be installed. Note that this extended installation is
Important:
Fast charging costs water! Check the water level in
your batteries regularly and top-up if necessary. Do not overfill!
Gel batteries (Exide specification)
: This is the new
optional and is not required for the unit to work.
specification for gel batteries as laid down by Exide. The
absorption voltage is 14.4V.
Battery Temperature:
Using its ring terminal end, connect
one of the enclosed temperature sensors to your domestic
(1)
Gel batteries (U.S. specification)
: This is the standard U.S.
battery’s
negative
post.
Do not use any positive battery terminal
specification for gel batteries. The absorption voltage is 14.1V.
for this connection!
Connect the two small wires on the other end
to the small terminals marked “battery temp”. Be careful not to
Sealed lead-acid batteries
and
AGM batteries
: These batteries
damage or alter the temperature sensor in any way! The system
are also charged at an absorption voltage of 14.4V, however with
will then sense the battery temperature and change the output
a shorter absorption time.
voltage in accordance with the recommended temperature
compensation for the selected battery type.
The ideal absorption time for each battery type is recalculated
automatically for each new charging cycle.
Important:
All voltages indicated in these instructions refer to an
ambient temperature of 20°C. When using a battery temperature
sensor these voltages will be different due to temperature
Start-Up and Test Procedure
compensation.
As soon as the unit is connected, it senses the output voltage
Alternator Temperature:
(10)
Using its ring terminal end,
from the alternator. When the alternator is producing voltage, the
connect one of the enclosed temperature sensors to your
alternator-to-battery charger will start up, indicated by a slow
alternator case or negative stud.
Do not use any positive terminal
flashing of the top green LED. The start-up phase will be about 2
(B+) for this connection!
Connect the two small wires on the other
to 3 minutes during which the unit is only working as a passive
end to the small terminals marked “alt temp”. Be careful not to
split charge device.
damage or alter the temperature sensor in any way! The system
When the start-up phase is completed, the top green LED (1) will
will then sense the alternator temperature and will disengage the
come on constantly, indicating that the unit is now in the constant
voltage amplifier if the alternator temperature exceeds 100°C.
current phase and is boosting the current into the domestic
battery bank. At the same time, the load on the alternator will
Voltage Sensing:
(3)
The alternator-to-battery charger in its
increase.
standard configuration senses all voltages directly at the unit.
However, in order to compensate a possible voltage drop
The voltage on the domestic battery output will then rise until it
between the unit and your domestic battery, you can run a simple
reaches the absorption voltage for the selected battery type.
0.5mm² wire from the positive stud of your domestic battery to the
After that the output will be kept constant on absorption voltage
terminal marked “dom sense”.
(14.1V to 14.8V) and the yellow timer LED (2) will come on. The
unit’s intelligent software automatically calculates the optimum
Starter solenoid:
(4)
Some alternators will not fire up without a
absorption time (between 1 and 24 hours.)
voltage on their B+ terminal. Because the alternator-to-battery
When the batteries are fully charged, the voltage will be reduced
charger contains a split charge diode there will be no voltage feed
to a constant float voltage (13.6V to 13.8V).
on the B+ terminal which means that the engine will start but the
During the boost and the absorption phase the entire charging
alternator may not work. If this is the case, then you need to use
cycle is suspended for 3 minutes every 20 minutes to provide
the starter solenoid feed terminal on the alternator-to-battery
additional charge capacity for the starter battery.
charger. It connects to the starter motor terminal which only
becomes live when the starter motor bendix is engaged, i.e. the
If, thereafter, the voltage of the domestic battery drops below
3
12V (e.g. due to a high load on the batteries), the entire charging
voltage (> 15.5V) on the alternator. It usually means that the
cycle will be repeated.
alternator’s own regulator has failed.
Check the voltage and, if
necessary, stop your engine as soon as possible and disconnect
the alternator input cable, or you will boil and destroy your
batteries!
Troubleshooting
Unit is not working at all (no LEDs)
LED 8 - HIGH ALT TEMP, STOP (yellow)
After you have started the engine, check the voltage at the main
This LED will come on when the alternator temperature as
alternator input of the unit. You should be able to measure at least
sensed by the unit, is above 90°C. The charge cycle will be
13V. If you do not measure any voltage at all, it is possible that
suspended until the alternator has cooled down to 75°C or below.
your alternator requires a voltage on the output to fire up. (See
A flashing yellow LED means that the alternator-to-battery
Extended Installation.) In this case connect an extra wire from the
charger is overheated. The charge cycle will be suspended until
terminal named “STARTER SOLENOID” to the positive terminal
the unit has cooled down. If this fault occurs regularly, then the
of the starter solenoid.
unit must moved to a cooler location to protect it from permanent
If the input voltage on the unit is 13V or above and you still can’t
damage.
see any LEDs lighting up, check the internal fuse of the unit
and replace if necessary. If the new fuse blows again, please
(7)
LED 9 - UNIT FAILURE
RHS
(red)
contact the Sterling customer service.
This LED warns you that the unit’s integrated split charge diode
has failed on the right hand side. Restart the unit. If the fault
Unit is not boosting the voltage
persists, please contact the Sterling customer service.
Most regulators come set with a standard output between about
13.8V and 14.4V. If the standard regulator does not work within
LED 10 - UNIT FAILURE
LHS
(red)
these limits and has an output voltage below 13.8V, then the unit
This LED warns you that the unit’s integrated split charge diode
may not boost. In this case set the regulation voltage switch
(14)
has failed on the left hand side. Restart the unit. If the fault
to the “ON” position. This will drop the engine battery charge from
persists, please contact the Sterling customer service.
appr. 13V to appr. 12.8V which in turn improves the boost effect
on the domestic battery side.
1
2
3
4
5
6
7
8
9
10
CONSTANT CURRENT
Slow flash = inactive
TIME CONTROL ON
Warning: Do not do this unless you have the above-described
problem as this could result in a low engine start battery
performance.
FLOAT/POWERPACK
Appendix 1: LED Information and Alarms
LOW BATTERY V
LED 1 - CONSTANT CURRENT (green)
A constant green LED (with LED 2 off) indicates that the unit is in
the bulk charge phase.
A flashing green LED indicates that the unit is in pause mode to
provide additional charge capacity for the starter battery.
HIGH BAT V/ TEMP (FL)
BATTERY TYPE
LED 2 - TIME CONTROL ON (yellow)
This LED indicates that the voltage is approaching or has
reached the absorption level. It will come on only in addition to
LED 1.
HIGH ALT VOLTS
HIGH ALT TEMP STOP
LED 3 - FLOAT/POWERPACK (green)
This LED indicates that the absorption charge has been finished
and that the batteries have been fully charged. It remains on until
the unit is switched off or until the next charge cycle starts.
UNIT FAILURE
UNIT FAILURE
LED 4 - LOW BATTERY V (orange)
This LED will come on when the domestic battery voltage as
sensed by the unit, is below 13V. Often this indicates a defective
alternator or battery.
Appendix 2: Unit Connectors
Make sure alle cables used have a suitable size!
LED 5 - HIGH BAT V/ TEMP (FL) (red)
A constant red LED means that the unit has tripped because of
TO DOMESTIC BATTERY BANK
high voltage at the domestic battery. Often, this indicates a failure
of the alternator regulator or another charging unit.
The positive connection leading to the domestic battery bank.
A flashing red LED means that the domestic battery temperature,
MAIN ALTERNATOR INPUT
as sensed by the unit, is above 50°C and that the charge cycle
has been suspended. Often, this indicates a defective battery.
The positive connection to be connected to the alternator B+
terminal.
LED 6 - BATTERY TYPE (yellow, green, red)
This LED displays the battery type that the unit has been set up
TO ENGINE STARTER BATTERY
for. It will be
The positive connection leading to the starter battery.
!
yellow, for open lead-acid batteries,
!
green, for gel batteries (Exide specification)
NEGATIVE CABLE
(17)
!
flashing green, then off, for gel batteries (U.S. specification),
Connect this wire to the alternator negative. Extend as required
using a 60A cable.
and
!
red, for sealed lead-acid and AGM batteries.
STARTER SOLENOID (optional)
The connection leading to the starter solenoid feed. (See
(4)
LED 7 - HIGH ALT VOLTS (red)
Extended Installation.) Use only if required!
This LED indicates that the unit has tripped because of high
4
 REMOTE DOM SENSE
(3)
(optional)
REMOTE CONTROL
(5)
(optional)
The connection leading to the positive terminal of the domestic
Connection for the optional remote control.
battery. (See Extended Installation.) Installation is optional.
ALTERNATOR INPUT SHUNT (optional)
ALTERNATOR TEMP SENSOR
(2)
(optional)
Connection for the alternator input shunt which is part of the
Connection for the alternator temperature sensor. Installation is
remote control package.
optional.
STARTER BATTERY SHUNT (optional)
BATTERY TEMP SENSOR
(1)
(optional)
Connection for the starter battery shunt which is part of the
Connection for the battery temperature sensor. Installation is
remote control package.
optional.
U
NIT
E
XPECTATIONS
What do I expect to see from this unit and why?
This is what the process is all about.
The below test was set up and monitored and is as close as
The steps on the graphs show the unit boosting every 15
possible as to what happens on the average split charge system.
minutes, then resting for 2.5 minutes. An example of this is the
The engine battery is a 100 amp hr standard lead-acid, and the
time period between and . What you can see here is that by
2
3
domestic battery is 3 x 100 amp hr standard lead-acid. The engine
switching off the amplifier (to help the engine battery getting more
battery was discharged to 11 volts (about 10 engine starts) and
charge), the engine battery voltage curve increases during that
the domestic bank to about 11 volts (will no longer run an inverter
step shown at point which results in extra current going into
6
and is about 60% empty). The alternator used is a Bosch 90 amp
the engine battery at position . The current change of this
7
with a standard 13.9 volt (variable) regulator. The unit battery type
process is reflected in the other graph marked ‘the current graph’.
is programmed to open lead-acid. There are two graphs, one is
The current graph
shows the current flow into the engine start
showing the current going into the batteries, and the other is
battery and the domestic system. The effect of the amplifier can
showing the various voltages on the system.
be clearly seen when the unit switches off for its 2.5 minutes rest
System Voltage Graph
:
cycle. The current drops from position = 95 amps to position
9
12
The key points to pick up on here are:
= about 20 amps, a huge difference. At the same time you can
The yellow trace (alternator voltage into the unit) clearly shows
see the extra current going into the starter battery which clearly
that the system is doing its job. It is designed to pull this voltage
charges through the whole exercise.
down a little in order to enable the standard alternator regulator to
On completion the unit switches off, and the process continues as
produce its full current. You can clearly see that on position on
4
a conventional split charge system . If however the domestic
10
the voltage curve the voltage is pulled down to position . The
5
battery falls below 12 volts, the system will automatically restart
current has increased from position - which is about 70
and continue the process again.
8
9
amps improvement.
shows that the engine battery has been fully charged and is
11
Position : This is the magic point, the point where the
1
taking no more current.
domestic battery voltage exceeds the alternator input voltage.
Engine battery bank, domestic battery bank, and alternator voltage curves
15.00
2
3
14.50
6
14.00
10
4
1
alternator input voltage
starter battery voltage
domestic battery voltage
5
13.50
13.00
time in mins
TIME min.
12.50
Domestic battery bank current curve, with engine battery bank current curve
9
100
90
80
70
60
50
40
30
20
domestic battery current
starter battery bank current
8
12
7
10
0
11
10
Time min.
time in mins
5
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