MEAN WELL PB-1000 (01) PDF Document

The MEAN WELL PB-1000 must be installed in a dry and well ventilated area. It should not be exposed to rain or snow.

The cables between the MEAN WELL PB-1000 charger and the battery should be kept as short as possible to prevent excessive voltage drop. Too much voltage drop will lead to a longer charging period.

Please make sure the charging voltage and current meet the battery specification when using the MEAN WELL PB-1000.

The MEAN WELL PB-1000 charger should be in the OFF mode before making battery connection or disconnection.

Double-check battery polarity before making the battery connection. The positive terminal of the charger must be connected to the + of the battery and the negative terminal to the – of the battery. Also, make sure the positive and negative terminals of the charger are not accidentally shorted together.

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.

According to the derating curve for the MEAN WELL PB-1000, the charging current is 100% from an ambient temperature of -20°C up to 40°C. At 50°C, the charging current drops to 80%. At 60°C, it drops to 60%, and at 70°C, it drops to 40%.

The function description for pins 1 and 2 (RY13) on the CN100 connector is as follows:

Relay contact rating (max.): 30V/1A. “Short” when bank A is full. “Open” when bank A is still charging.

The function description for pins 3 and 4 (RY14) on the CN100 connector is:

Relay contact rating (max.): 30V/1A. “Short” when bank B is full. “Open” when bank B is still charging.

The function description for pins 5 and 6 (RY15) on the CN100 connector is:

Relay contact rating (max.): 30V/1A. “Short” when the unit is working properly. “Open” when the unit has failed or protection has activated.

Pins 7 and 8 (GND/RTH) on the CN100 connector are for the temperature sensor which comes with the charger. This sensor can be connected to the unit to allow temperature compensation of the charging voltage. If the temperature sensor is not used, the charger can still work normally.

The output can be turned ON and OFF by electrical or dry contact between pin10 (RC+) and pin9 (RC-). An open circuit starts charging, and a short circuit stops charging.

The LED indications for the battery status on the MEAN WELL PB-1000 are as follows:

The types of failure indicated by the Red LED on the MEAN WELL PB-1000 are:

1 Battery disconnected

2 Damaged battery

3 Reverse polarity

4 Incorrect battery voltage (e.g. PB-1000-12 connected to 24V battery)

5 Activation of protection function (e.g. OTP, OVP, and Short)

For 2 stage charging mode on the MEAN WELL PB-1000, the stages and LED colors are:

Stage 1 (Constant Current): LED Color is Orange.

Stage 2 (Constant Voltage): LED Color is Orange.

Battery Full: LED Color is Green.

For 3 stage charging mode on the MEAN WELL PB-1000, the stages and LED colors are:

Stage 1 (Constant Current): LED Color is Orange.

Stage 2 (Constant Voltage): LED Color is Orange.

Stage 3 (Battery Full/Float Voltage): LED Color is Green.

For 8 stage charging mode on the MEAN WELL PB-1000, the stages and LED colors are:

Stage 1 (Pulse charging) and Stage 2 (Soft Start) show an Orange LED color.

Stage 3 (Constant Current), Stage 4 (Constant Voltage), Stage 5 (Analysis), Stage 6 (Recondition), Stage 7 (Float), and Stage 8 (Maintain) all have a Green LED color when the battery is full or near full capacity.

The initial stage (battery analysis) for the MEAN WELL PB-1000 checks the 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.

During Stage 1 (constant current) for the MEAN WELL PB-1000, a constant current is provided so the battery can be quickly charged to 2.4V per cell.

During Stage 2 (constant voltage) for the MEAN WELL PB-1000, a constant voltage of 2.4V per cell is provided until the charging current naturally tapers down to 10% then charging stops.

During Stage 1 (constant current) in the 3 stage charging mode of the MEAN WELL PB-1000, the charger will provide maximum current to the battery, and the built-in fan will turn ON. As the battery starts to get full, the charging current will gradually decrease (programmed to last no longer than 24hrs).

During Stage 2 (constant voltage) in the 3 stage charging mode of the MEAN WELL PB-1000, when the charging current decreases to less than 10% of max, the LED indicator will turn Green to show a full charge. The charger will then maintain a float charge voltage (Stage 3).

Stage 3 (Float voltage) for the MEAN WELL PB-1000 involves providing a float voltage of 2.3V per cell for an extended period so that the battery can maintain full charge.

The advantage of pulse charging in Stage 1 of the 8 stage charging for the MEAN WELL PB-1000 is that it uses pulse current to revive aged batteries that are either improperly charged/discharged or allowed to self-discharge during non-use, helping to restore their normal chemical properties.

Stage 2 (soft start) in the 8 stage charging for the MEAN WELL PB-1000 uses a low charge voltage and current to prepare the battery to accept upcoming bulk charging, enabling a better charge to be applied.

During Stage 5 (analysis) for the MEAN WELL PB-1000, the charger will stop charging for 2 minutes to determine battery status. If the battery voltage is 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.

During Stage 6 (recondition boost charge) in the 8 stage charging for the MEAN WELL PB-1000, boost voltage is provided to recondition the battery storage capacity to its original state.

During Stage 7 (float charge) in the 8 stage charging for the MEAN WELL PB-1000, a float voltage of 2.3V per cell is provided for an extended period of time so that the battery can maintain full charge.

During Stage 8 (maintain) in the 8 stage charging for the MEAN WELL PB-1000, maintenance charge is provided to compensate for battery self-discharge and extend battery life.

The input voltage range for the MEAN WELL PB-1000 is 90~264Vac or 127~370Vdc. 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.

The built-in active PFC circuit of the MEAN WELL PB-1000 achieves PF>0.95 when the input voltage is between 90~230Vac with full load at the output. If the input voltage is >230V or the output is not at full load, the PF will drop below 0.95.

The charger can be turned ON/OFF by using the “remote control” function via the connection between RC+ (pin10) and RC- (pin9) on the CN100 connector:

The MEAN WELL PB-1000 charger can be hooked up to two battery banks (A and/or B). If connecting 2 battery banks at the same time, keep in mind that they must share a common ground.

The charging profile on the MEAN WELL PB-1000 is selected by moving the slide switch on the back panel according to the following:

The MEAN WELL PB-1000 has a built-in battery reverse polarity detection circuit. When the battery is connected in reverse at the output terminal of the charger, the output relay circuit will remain open.

The MEAN WELL PB-1000 has a built-in fan speed control circuit, so the fan will automatically change speed depending on the load condition.

The status of the Charger OK relay (RY15) on the MEAN WELL PB-1000 between pin5 and pin6 is:

The status of the Bank A OK relay (RY13) on the MEAN WELL PB-1000 is:

The status of the Bank B OK relay (RY14) on the MEAN WELL PB-1000 is:

The temperature sensor that comes with the MEAN WELL PB-1000 can be connected to the unit to allow temperature compensation of the charging voltage. If the temperature sensor is not used, the charger can still work normally. The temperature sensor can either be attached to the battery or placed in its surrounding environment (NTC connection at pins 7 and 8).

The recommended minimum wire gauge for connection to the MEAN WELL PB-1000 based on the Max. Current(A) rating (UL1015(600V 105℃)) is:

RED wire is highly recommended for the + connection and BLACK wire for the – connection.

The suggested battery capacity range for the PB-1000-12 model of the MEAN WELL PB-1000 is 200-600AH.

The suggested battery capacity range for the PB-1000-24 model of the MEAN WELL PB-1000 is 120-350AH.

The suggested battery capacity range for the PB-1000-48 model of the MEAN WELL PB-1000 is 60-175AH.

When two 12V 100Ah batteries are connected in series to the MEAN WELL PB-1000, the voltage is doubled, resulting in 24V 100Ah. The capacity (Ah) remains the same.

When two 12V 100Ah batteries are connected in parallel to the MEAN WELL PB-1000, the voltage remains the same, and the capacity (Ah) doubles, resulting in 12V 200Ah.

If the ON/OFF switch on the MEAN WELL PB-1000 is in the OFF position and the battery is unable to charge, the solution is to switch to the ON position.

If the LED indicator on the MEAN WELL PB-1000 does not turn Green after a long charging period due to battery reverse polarity, the solution is to reconnect using the right polarity.

If the battery connected to the MEAN WELL PB-1000 is unable to charge because it has a higher voltage than expected, the solution is to use a battery with the correct voltage.

If the input AC voltage to the MEAN WELL PB-1000 is too low and the battery is unable to charge, make sure the input source is between 90~264VAC.

If the LED indicator on the MEAN WELL PB-1000 does not turn Green after a long charging period because the battery exceeded its lifespan or is damaged, the solution is to replace it with a new battery.

If the LED indicator on the MEAN WELL PB-1000 does not turn Green after a long charging period due to output cables being too thin, the solution is to replace them with a suitable wire gauge.