Chargetek ctbnk2 Manual

CTBNK2-WP Manual
Table of Contents
Product Description 2
Initial Setup 3
Configuration 5
Status Display 10
Diagnostic Testing 13
Charging Algorithms 15
Glossary 18
If you come across a word or concept you are not familiar with please refer to the Charging Basics section
and the glossary. You will find information regarding charging cycles and stages, useful vocabulary, and
explanations of units.
Chargetek 409 Calle San Pablo, Unit #104, Camarillo, CA 93012 Tel: (805) 482-7930 Fax: (805) 482-7936 www.chargetek.com
Product Description
The CTBNK2-S01 is a dual bank, intelligent charging system for several types of lead based 12V
batteries such as SLA, AGM, flooded, and maintenance free. With a wide operating temperature
range (-20C to 50C) and an environmentally rugged and waterproof design, it is especially suited for
high end industrial and military applications. The CTBNK2-S01 is completely sealed from dust and
other environmental contaminants. Each bank is independent and electrically isolated. The
CTBNK2-S01 precisely implements a user defined charging algorithm and controls the charging
voltage and current to ensure a complete recharge every time. An informative graphical user
interface clearly displays voltage, current, and charging status in real time. It also provides a means
for the user to precisely define the charging algorithm for each battery. The charging system weighs
11 pounds and is easily mountable.
Initial Setup
Fig. 1. Initial Setup
Startup Menu
1 2 3 4
Fig.2. Startup Menu
This is the startup menu. It is what you will see when you turn on the charger.
To configure the charger press either the button labeled 2 in the image above or the button labeled 3.
Choose the button that is beneath the label for the bank you would like to charge and see page 7 for further
instructions.
To use settings specified previously and view the status of the charger press the button labeled 1 above
and see page 10 for an explanation of the information provided on the textual and analog status display.
To execute a service configuration of the charger press the button labeled 1 above to go to the textual or
analog status display, and follow the instructions found on page 8.
If you are unsure whether to complete basic or service configuration press the button labeled 1 above to go
the textual or analog status display, and go to page 5 for help.
Configuration
Select Basic Config in the textual or analog status display if you would like to:
change from a 3 stage to a 4 stage charging cycle or vice versa

indicate that the battery type is different than what shows up in the textual or analog display
reset the charger to apply changes made in a configuration menu
For basic configuration instructions go to page 6.
Go to page 8 for service configuration instructions if you:
Have the service configuration code
AND would like to
indicate specific charging algorithm

indicate maximum absorption stage time
indicate maximum equalization stage time
indicate maximum dV/dT time
run diagnostic mode
Basic Configuration
1 2 3 4
Fig.2.(2) Startup Menu
When Basic Config is selected in the main status display the startup menu will appear again.
Press the button under the bank you would like to configure (labeled 2 for Bank 1 and 3 for Bank 2
above) and it will take you to the configuration display shown on the next page.
1 2 3 4
Fig.3. Setup Menu
Each of the three settings that can be changed from the setup menu has two options.
Pressing the button labeled 1 above allows you to change from a 3 stage to a four stage charging
cycle and back, without/with equalization respectively.
Pressing the button labeled 2 above allows you to indicate what type of battery is charging in the
bank you are configuring (shown at the top of the display). The options you have to select from are
AGM and flooded (FLD). Select the type that is labeled on the battery you are charging.
Pressing the button labeled 3 above allows you to turn the output off and on. It must be on to
charge the battery in the bank you are configuring. If you make a change to either or both of the
two leftmost setting menus while the output is on you must turn the output of an on again to
apply this change.
To return to the startup menu press the button labeled 4 above under Done.
Service Configuration
Fig.4. Service Configuration Menu
Press the Service Config button in the textual or analog status display for the bank you would like to
configure. You will be prompted for a code which you can enter using the buttons beneath the numbers. If the
correct code is not entered after a certain period of time the buttons on the textual or analog status display will
return to their initial functions. Once the code is entered correctly you will see the service configuration menu
shown above. You can tell which field is selected by the red rectangle outlining it. In the example above,
AGM Type is selected. The Select Up and Select Down buttons move the rectangle to the next or
previous field so you can change the selection there. For example, pressing the button under Select Down
on the screen shown above would move the red rectangle from AGM Type to Flooded Type. Pressing the
Modify Value Next and Modify Value Prev buttons allow the value outlined in red to be changed.
Below is information on the values that are available for each field on the configuration display.
AGM Type: If an AGM battery is connected to the back specified at the top of the display this allows you
to select one of the three AGM charging algorithms (see page 15 for more information.)
Flooded Type: If a flooded type battery is connected to the back specified at the top of the display
this allows you to select one of the two flooded type charging algorithms (see page
15 for more information.)
Max Absorb Time: Sets the maximum time the charger will remain in the absorption cycle, adjustable
from 1 to 24 hours in half hour increments. Used to limit charge times in the
absorption mode. For example, in the case where the battery may have a DC load
connected, not allowing the charger current to drop to the float transition level from
the absorption cycle until the end of the Max Charge Time limit.
Max Equalization Time: In the equalization mode the charger output is limited to small charge current and
will transition to the float mode once the charge current drops to a smaller
predetermined value. The amount of time the charge should be in the equalization
mode should be limited. This configuration items sets the maximum time the
charger can be in the equalization mode, the value is adjustable from 2 to 17 hours
in one hour increments
Max dV/dT Time: Selectable from 1V/1hour to 1V/16 hours in 1 hour increments. If the charger output
voltage increases at a rate less than the rate specified while in the fast or
absorption mode, the charger will go into float mode. Enabling monitoring of the
dV/dT rate may be desirable in situations where loading of the battery or a
defective battery does not allow the battery voltage to ever rise to the full charge
level.
Diagnostic Mode: See page 13 for instructions.
When the Return to Status Display field is selected (outlined in red), the labels over the two rightmost
buttons change to Return and Save and Return and Discard. Selecting Return and Save will save and
apply the changes you made to the charger configuration and return to the textual or analog status display.
Selecting Return and Discard will ignore any changes made and return to the textual or analog status
display.
Status Display
Analog Textual
Fig.5. Analog Status Display Fig.6. Textual Status Display
In the textual or analog status display you will see current charging information displayed as shown in the
image on the left. The image on the right is a second option for viewing this information--in text as opposed to
on meters--it also allows you to see what type of battery is charging in each bank (Bat Type). These two
displays are referred to as the analog and textual Status Displays. To switch from the analog to textual
display or vice versa, press the button under Switch Display.
Mode: The information next to the Mode label on the analog or textual status display lets you know which
charge mode is currently active in each bank. If a battery is not in one of the charging modes it will show one
of the other possible statuses defined on the following page.
10
Charge modes:
PRECRG: Charging a battery from a low charge state, output current is set to a lower value until
the voltage rises to a predetermined level, this mode is followed by the Bulk charge
BULK: Bulk charging mode
ABSOR: Absorption charging mode
FLOAT: Float charging mode
EQUAL: Equalization charge mode
AU-EQ: Automatic Equalization mode (the charger has detected a problem with the battery and is
trying to repair it).
Other possible statuses:
SHUTDN: The charge has shut down to a fault condition, this message alternates with the
detected fault condition which can be one of the following:
Over V, the output voltage has exceeded the maximum rate. If this condition persists
after a power cycle the charger must be replaced
Over T, the charge temperature has exceeded its maximum operation level, check that:
the charger has a minimum clearance of 4 inches surrounding the charger
is not in an airtight enclosure
is not in direct sunlight
is not near any heat generating sources.
Reverse, the battery is connected reverse polarity.
No Bias, may be caused by extreme over temperature condition. If this condition persists
after a cool down period and a power cycle the charger must be replaced.
NOBAT: No battery has been detected at the output of the charger
REV: The connection from the charger to the battery is reversed (reverse polarity)
SRCHNG: Searching for a battery, dependent on battery charge algorithm
Mode charge time: In the display with meters this is the first time under each bank. In the textual display it is
the time under each bank that is in the row labeled Mode Charge Time. It shows you how long the charger
has been in the current charge mode.
11
Total charge time: In the display with meters this is the second time under each bank. In the textual display it
is the time under each bank that is in the row labeled Total Charge Time. It shows you the combined time
that the charger has been in the bulk, absorption, and float modes.
Charger Temperature: Next to Charger Temperature in the display with meters, and in the row labeled
Temperature in the textual display, you will see the temperature of the charger in degrees celsius and
fahrenheit.
Battery type: In the textual status display you will see a row labeled Bat Type her you can see the type of
battery being charged which corresponds to the charging algorithm currently being used. The typical charging
algorithms available are shown below but will vary with specific models.
SLA: Standard lead acid battery

AGM: Absorption glass mat battery
DeepCy: Deep cycle battery
Oddsy: Odyssey type battery
The buttons function as follows while in the textual or analog status display:
Label Function
Service Config 1: See page 8 for details.
Service Config 2: See page 8 for details.
Basic Config: Press to return to startup display.
Switch display: Switched from analog to textual status display or vice versa.
12
Diagnostic Testing
Diagnostic mode display
Diagnostic mode can be used to check that the charger is operating properly in each mode individually. The
output will turn on without the presence of a battery when in the Diagnostic mode, this is so a voltmeter can
be connected to the output allowing you to check the operation of the charger in each charging mode.
If you move your selection to the Diagnostic Mode row on the service configuration display and use
the button under Modify Value to select on, the button labels will change to what is shown below,
and you will be able to test the functioning of the charger in different charging modes and with
different charging algorithms.
13
Fig.7. Diagnostic Mode Display
The buttons function as described below while in the diagnostic mode:
Label Function
DIAG OFF: Turns off diagnostic mode and returns to the Configuration display.
Mode: Cycles through absorption, equalization, and float charging modes allowing you to select a
mode. The charge will only remain in the selected mode while in the diagnostic mode.
On/Off: Toggles the output on or off.
Batt: Cycles through the five available battery charge algorithms (AGM 1, 2, 3 and FLD 1, 2). This
only affects the output voltage.
In the diagnostic mode, the charger operating parameters are displayed in real-time at the bottom of the
display. These parameters include:
Chrg Volts - Charger voltage (internal charger voltage)

Battery Volts - Battery voltage (output voltage of the charger)
Mode - Charger Mode
Chrg Cur - Output charge current
14
Charging Algorithms
Four stage charging cycle
Four stage charging supplies constant current to battery until absorption voltage is reached
(VFSTERM). Transition to absorption mode follows and regulates battery voltage at VFSTERM until
current decreases to IABTERM. Float mode follows and regulates battery voltage at VFL. At the user's
discretion, an equalization mode can be initiated.
Fig.8. Four Stage Charging Cycle
Stage 1: Constant current charging or bulk charge mode
Assuming the battery is starting in a discharged state, the charger is operating in constant current
mode, where the charger current is maintained at a constant value and the battery voltage is
allowed to rise as it is being recharged. Approximately 80% of battery capacity is returned in the
constant current region.
Stage 2: Absorption mode
When the battery voltage reaches approximately 2.4 volts per cell, or 14.6 volts for a 12V battery,
the charger voltage is held constant at this level and the battery current is allowed to reduce. It is
this region where the last 20% of battery capacity is returned. This voltage level is maintained until
the battery current reduces to approximately C/50 to C/100, where C is the amp-hour rating of the
15
battery. For instance, if it is a 100 amp-hour battery, the voltage should be maintained at 2.5V per
cell until the current decreases to 1-2 amps. The exact amount is not usually critical.
Stage 3: Float mode
At the point where the current is reduced to C/50 to C/100, the battery charger enters float mode.
Float mode is where the voltage on the battery is maintained at approximately 2.25 volts per cell, or
13.5 volts for a 12V battery. This voltage will maintain the full charge condition in the battery without
boiling our electrolyte or overcharging the battery.
Stage 4: Equalization mode
The purpose of the equalization mode is to remove the sulphation from the lead plates and to
eliminate the stratification of the electrolyte. Approximately 2.5-2.6 volts per cell is applied to the
battery with the charging current set to a very low value, typically less than 0.5 amp. The
equalization mode may last anywhere from a few hours to over 24 hours depending upon
circumstances.
16
AGM 1 FLD 1
Mode Absorption Float Equalization Mode Absorption Float Equalization
Voltage 14.4 13.5 15.5 Voltage 14.5 13.2 15.5
Startup Sequence Startup Sequence
If the Battery Voltage > 5V start charging, limiting the current to 1 Amp to up If the Battery Voltage > 5V start charging, limiting the current to 1 Amp to
to a battery voltage of 6.5V. Above 6.5V and below 10.5V the current is up to a battery voltage of 6.5V. Above 6.5V and below 11V the current is
limited to 4 amps. limited to 5 amps.
If the Battery Voltage < 5V, pulse the battery two times for 450ms with a If the Battery Voltage < 5V, pulse the battery two times for 450ms with a
150ms delay between pulses, wait 5 seconds and check for battery voltage 150ms delay between pulses, wait 5 seconds and check for battery
to be above or below 5V, repeat until battery voltage is > 5V. If there is no voltage to be above or below 5V, repeat until battery voltage is > 5V. If
voltage, i.e. 0V, after a pulse group is applied the battery is most likely there is no voltage, i.e. 0V, after a pulse group is applied the battery is
reversed and the charger is shut down. most likely reversed and the charger is shut down.
AGM 2 FLD 2
Mode Absorption Float Equalization Mode Absorption Float Equalization
Voltage 14.4 13.6 15.5 Voltage 14.6 13.4 15.5
Startup Sequence Startup Sequence
If the Battery Voltage > 5V start charging, limiting the current to 1 Amp to up If the Battery Voltage > 5V start charging, limiting the current to 1 Amp to
to a battery voltage of 6.5V. Above 6.5V and below 10.5V the current is up to a battery voltage of 6.5V. Above 6.5V and below 11V the current is
limited to 4 amps. limited to 5 amps.
If the Battery Voltage < 5V, pulse the battery two times for 450ms with a If the Battery Voltage < 5V, pulse the battery two times for 450ms with a
150ms delay between pulses, wait 5 seconds and check for battery voltage 150ms delay between pulses, wait 5 seconds and check for battery
to be above or below 5V, repeat until battery voltage is > 5V. If there is no voltage to be above or below 5V, repeat until battery voltage is > 5V. If
voltage, i.e. 0V, after a pulse group is applied the battery is most likely there is no voltage, i.e. 0V, after a pulse group is applied the battery is
reversed and the charger is shut down. If after 6 groups of pulsing the most likely reversed and the charger is shut down.
voltage is still < 5V start charging, limiting with the current to limited to 4
amps until the voltage reaches 10.5V.
AGM 3
Mode Absorption Float Equalization
Voltage 14.51 13.5 15.5
Startup Sequence
If the Battery Voltage > 5V start charging, limiting the current to 1 Amp to up
to a battery voltage of 6.5V. Above 6.5V and below 11V the current is limited
to 6 amps.
If Battery Voltage < 5V, pulse the battery two times for 450ms with a 150ms
delay between pulses, wait 5 seconds and check for battery voltage to be
above or below 5V, repeat until battery voltage is > 5V. If there is no voltage,
i.e. 0V, after a pulse group is applied the
battery is most likely reversed and the charger is shut down.
17
Glossary
Ampere: SI unit for the amount of electrical charge traveling through a conductor per second.
Absorption mode: The charging state during recharge where a lead acid battery accepts the final
15-25% of its capacity. The voltage for a 12V lead acid battery is regulated at
approximately 14.6V during absorption while the battery acceptance current
continually decreases.
Battery: Two or more electrochemical cells electrically connected in a desired series/parallel

arrangement to achieve a particular voltage/current capability.
Battery Charge Algorithm: The sequence of applying a controlled voltage or current to the battery as a function
of time in state of charge.
Bulk mode: The charging state during recharge where a lead acid battery accepts the 75-85%
of its capacity. The charging current for a 12V lead acid battery is regulated at its
maximum current output while the battery voltage continually increases until the
absorption stage is reached.
Capacity: The total number of ampere-hours (or watt-hours) that can be delivered by a battery
under specified conditions of discharge, such as current draw and temperature.
Cell: The fundamental electrochemical unit generating or storing electrical energy. For
instance, a lead acid 12V battery is obtained by placing in series six cells of 2V
each.
Charging: The process of converting the current supplied to a battery from an external source
into chemical energy stored by the battery for later use.
Cycle: The discharging and charging of a rechargeable battery. Many manufacturers

provide the number of charge/discharge cycles that a rechargeable battery can
undergo before a measurable decrease in specification performance.
Discharge: The internal conversion of the chemical energy stored in the battery into electrical
energy for outside use.
Discharge rate: The rate of current draw expressed in amperes, to indicate the amount of energy
being delivered by the battery.
Electrolyte: The chemical providing the ion transport mechanism between the positive and
negative electrodes of a cell.
Efficiency: The ratio of total output power to input power expressed as a percentage.
Float mode: The maintenance state following bulk and absorption where a lead acid battery is at
full capacity. The voltage for a 12V lead acid battery is regulated at approximately
13.5V during float and remains there indefinitely for long term storage. Internal
18
battery losses are replenished by the charger during float to maintain the battery at
full capacity.
Overcharge: Charging beyond the point where the full capacity of the battery occurred.
Reverse polarity: When the charger leads are connected in reverse (plus charger to minus battery,
etc.).
Volt: SI unit for the measurement of voltage, defined as joules (energy) per unit of
electrical charge (coulombs). Voltage in laymen terms is commonly referred to as
the amount of electrical pressure available to produce a current flow through a
given resistance.
Voltmeter: An instrument used to measure voltage. The unit for the measurement of voltage is
volts.
Waterproof: Designed such that water and moisture will not enter the enclosure under specified
test conditions.
Watt: SI unit for the measurement of power. For DC, the amount of power is obtained by
multiplying volts times amperes.
NOTE: Chargetek products are not authorized for use as components in life support systems, hazardous
environments, nuclear control systems or other similar applications without the express written consent of the
President of Chargetek , Inc. The appearance of products, including safety agency certifications pictured on
labels, may change depending on the date manufactured. Specifications are subject to change without notice.
19

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CTBNK2-WP Manual

Fig. 1. Initial Setup

Fig.2. Startup Menu

change from a 3 stage to a 4 stage charging cycle or vice versa

For basic configuration instructions go to page 6.

Go to page 8 for service configuration instructions if you:

Have the service configuration code

AND would like to

indicate specific charging algorithm

Fig.2.(2) Startup Menu

Fig.3. Setup Menu

Fig.4. Service Configuration Menu

Diagnostic Mode: See page 13 for instructions.

Fig.5. Analog Status Display Fig.6. Textual Status Display

trying to repair it).

Other possible statuses:

SLA: Standard lead acid battery

Service Config 1: See page 8 for details.

Service Config 2: See page 8 for details.

Basic Config: Press to return to startup display.

The buttons function as described below while in the diagnostic mode:

On/Off: Toggles the output on or off.

Chrg Volts - Charger voltage (internal charger voltage)

Fig.8. Four Stage Charging Cycle

Stage 1: Constant current charging or bulk charge mode

Stage 2: Absorption mode

Stage 3: Float mode

Stage 4: Equalization mode

Mode Absorption Float Equalization Mode Absorption Float Equalization

Voltage 14.4 13.5 15.5 Voltage 14.5 13.2 15.5

Startup Sequence Startup Sequence

Mode Absorption Float Equalization Mode Absorption Float Equalization

Voltage 14.4 13.6 15.5 Voltage 14.6 13.4 15.5

Startup Sequence Startup Sequence

Mode Absorption Float Equalization

Voltage 14.51 13.5 15.5

Battery: Two or more electrochemical cells electrically connected in a desired series/parallel

Cycle: The discharging and charging of a rechargeable battery. Many manufacturers

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