The Voltech BC-1230P/1240P/1260P is a series of multi-stage battery chargers designed for a wide range of applications, including automotive, marine, mobile homes, RVs, electric scooters, golf carts, solar, deep cycle, UPS standby, industrial, and commercial uses. These advanced chargers utilize a micro-processor to control charging profiles and protective functions, ensuring fast, complete, and gentle charging of lead-acid batteries.
Function Description:
The primary function of these chargers is to provide multi-stage (IU0U) switching mode battery charging. They are designed to charge both standalone batteries and batteries with connected loads. The innovative charging profiles adapt to the "state of charge" of the batteries, delivering the optimal current and voltage to prevent under or overcharging.
The chargers offer eight selectable charging profiles tailored for various battery types: Wet, Gel, AGM, LiFePO4, Calcium-Calcium, and Lead Crystal batteries. Additionally, two user-programmable charging profiles are available via a USB port and personal computer for professional users. A programmed maintenance charge includes a timely Equalization charge specifically for Wet lead-acid batteries.
The device incorporates comprehensive protective functions, all controlled by the micro-processor. Upon startup, the charger performs a series of self-tests on these protective functions, displays, and critical components like the cooling fan. An optional detachable remote control panel (HBR-3100) provides enhanced monitoring capabilities, displaying battery status, charger output, protection status, hours of operation, and more.
The charging process follows a 4-stage IU0U algorithm:
- I-Phase (BULK mode): Constant current charging. The battery is charged at its maximum constant current until it reaches the selected Absorption voltage level. A "Soft-Start Bulk Charging" mode reduces the current to half if the battery voltage is below 10.5V, gradually increasing it as the voltage rises. If the battery voltage doesn't reach 12.0V after 4 hours, the unit enters fault mode and shuts off.
- UO-Phase (ABSORPTION mode): Constant voltage charging. Once the battery voltage reaches the selected Absorption voltage level, the charger switches to constant voltage charging. The charging current gradually decreases until a preset value is reached, at which point the charger transitions to Float Stage.
- UO-Phase (FLOAT mode): Constant voltage charging. In this stage, the battery is full and only draws the necessary current to maintain its capacity. The float voltage is preset according to the selected battery type. If the charger remains in this mode with charging current less than 5A for over 72 hours, it automatically switches to Standby mode.
- UO-Phase (STANDBY mode): Constant voltage charging. This mode, applicable to certain battery types, reduces the charging voltage by 4% compared to the standard Float voltage. This helps reduce electrolyte drying out and prolongs the life of an inactive battery.
The charger also features a "New Cycle Charge" every 21 days, automatically initiating a new charging cycle (Bulk to Absorption to Float) from either standby or float mode. This refreshes the battery, preventing electrolyte separation and keeping electrode plates in good condition during long storage periods.
Usage Features:
The charger is designed for indoor use and must be protected from water ingress. It is specifically made for properly sized lead-acid batteries and should not be used for non-rechargeable or undersized batteries, as this could lead to fire or explosion. Installation must comply with all local codes.
Users can preset the maximum output (charging) current in 10% increments to match different battery capacities or loading conditions. This is done using a small slot-type screwdriver to select the desired current via the Charging Current Selection Switch (5) on the front panel. The selected output current can also be viewed on the optional remote panel.
Battery type selection is crucial and is performed using a small slot-type screwdriver on the Battery Selection Switch (4) on the front panel. Users must ensure the selected battery type matches the battery's specifications for Absorption and Float Voltage.
For dual bank charging, the feature supports two totally separate batteries. Both batteries must be of the same chemical makeup and capacity to avoid over and undercharging. They are charged simultaneously, with the battery having the lowest level receiving the most current during the Bulk stage until its voltage matches the second battery. Both batteries then proceed to Absorption and Float Charge together.
The charger can operate in "Power Supply Mode," providing a constant DC source to connected loads without a battery. This is useful for checking the operation of connected powered appliances.
An optional remote display (HBR-3100) can be installed to monitor real-time charging stage, voltage, amperage, battery type, power level, and fault information. It also allows remote control of the output terminal (ON/OFF), triggering Equalization charging for wet batteries, and forcing the charger to float mode. The remote display can be mounted on the charger's front panel or remotely with an extension cable.
Maintenance Features:
Regular maintenance includes checking battery condition, filling cells for wet batteries, and cleaning battery poles. The charger should be secured in a well-ventilated place, ensuring the mounting surface is flat and free of soft covering materials. Air intake is at the bottom, and the outlet is at the back; both must remain unblocked. The charger should never be placed on top of a battery.
For Wet lead-acid batteries, periodic higher voltage charging (Equalization) is recommended to balance cell voltage, reverse electrolyte concentration, and clear sulfate crystals. The Equalization Selection Switch (8) allows manual or auto equalization. Auto equalization starts if the charger remains in Float mode for over 21 days, running for 240 minutes before returning to Float mode. This mode is only for WET (Flooded) batteries, and special precautions must be taken due to explosive gas emission.
The temperature sensor (accessory) is used for optimal charging across a wide ambient temperature range. It must be installed at the Negative Terminal of the battery to avoid damage and ensure correct temperature control. The sensor compensates the charging voltage (20mV/C), lowering it at higher battery temperatures. If the battery temperature reaches 60°C, the charger will shut down, and fault/OTP indicator LEDs will light up.
For storage, if the RV or similar vehicle is in storage for an extended period without solar panels, it's recommended to leave the AC power connected and the charger on, ensuring all loads are turned off or disconnected from the battery. The charger's automatic Standby Charge Mode and 21-day New Cycle charge will manage the battery. Alternatively, if AC mains are disconnected, the battery charger should be disconnected from the battery. Regular checks of the charging process and battery condition are advised during unattended charging.
Troubleshooting guidance is provided for various issues, including the charger not working, no DC output, battery not getting a full charge, long charging times, and persistent Bulk light. Solutions range from checking AC connections and fuses to rechecking battery type selection, current settings, battery condition, and ambient temperature. For internal faults, the charger should be returned to the distributor for repair.
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