Sterling Power Products AB24100, AB12160, AB12210 Extended Installation, Battery Type Selection

run more often when the unit is installed in a place with a high ambient temperature.

Before connecting the unit to your alternator(s) make sure that your alternator-to-battery charger ist rated for the maximum output of the alternator(s).

Connect the main alternator output(s) (B+) to the centre stud marked “ALTERNATOR INPUT. Then simply connect the other studs to the engine battery and to the domestic battery, respectively. Make sure that the cables used can carry the full current of the alternator(s). Choose a cable size that can carry at least twice as much current than required. For example, if you have a 70A alternator, then use a 140A cable.

If you are only going to charge one bank of batteries, then use the “DOMESTIC BATTERY” output only. The “START BATTERY” output can remain unused without affecting the performance of the unit.

The unit has a short negative wire which has to be extended and connected directly to the alternator negative (or case) using a 60A cable.

If you currently have a split charge diode, then the three positive wires are already there. Simply replace the split charge diode with the alternator-to-battery charger and connect the negative wire to the alternator.

Important: If your alternator has got its own battery voltage sense wire, then this has to be removed from the battery terminal and should be connected to the alternator’s own B+ output instead. This will prevent contradictory regulation between the alternator and the alternator-to-battery charger.

Extended Installation

For additional functions and improved performance some extra features can be installed. Note that this extended installation is optional and is not required for the unit to work.

Battery Temperature: (1) Using its ring terminal end, connect one of the enclosed temperature sensors to your domestic battery’s negative post. Do not use any positive battery terminal for this connection! Connect the two small wires on the other end to the small terminals marked “battery temp”. Be careful not to damage or alter the temperature sensor in any way! The system will then sense the battery temperature and change the output voltage in accordance with the recommended temperature compensation for the selected battery type.

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 compensation.

Alternator Temperature: (10) Using its ring terminal end, connect one of the enclosed temperature sensors to your alternator case or negative stud. Do not use any positive terminal (B+) for this connection! Connect the two small wires on the other end to the small terminals marked “alt temp”. Be careful not to damage or alter the temperature sensor in any way! The system will then sense the alternator temperature and will disengage the voltage amplifier if the alternator temperature exceeds 100°C.

Voltage Sensing: (3) The alternator-to-battery charger in its standard configuration senses all voltages directly at the unit. However, in order to compensate a possible voltage drop between the unit and your domestic battery, you can run a simple 0.5mm² wire from the positive stud of your domestic battery to the terminal marked “dom sense”.

Starter solenoid: (4) Some alternators will not fire up without a voltage on their B+ terminal. Because the alternator-to-battery charger contains a split charge diode there will be no voltage feed on the B+ terminal which means that the engine will start but the alternator may not work. If this is the case, then you need to use the starter solenoid feed terminal on the alternator-to-battery charger. It connects to the starter motor terminal which only becomes live when the starter motor bendix is engaged, i.e. the

first two seconds of having the ignition key fully turned. During these two seconds, a 12 volt feed is sent to the alternator B+ terminal which is enough to let the alternator fire up. Thereafter, the alternator looks after itself. Use a 0.5mm² wire for this connection.

Multiple Alternators: The alternator-to-battery charger can be used on more than one alternator at the same time. Simply connect all alternator outputs (B+) to the alternator input terminal on the unit. Make sure that your alternator-to-battery charger is rated for the combined maximum output of the alternators.

Remote Control: (5) The remote control kit is an optional extra including a remote display and two 200A shunts. The two shunts measure the current coming from the alternator (9) and the current going into the starter battery (8). From these values the electronics will calculate the current going into the domestic battery.

The remote control will keep you informed about voltages, currents, temperatures and other operating figures. In the event of a problem, it indicates what the problem is.

Battery Type Selection

Programme the type of your domestic battery into the unit by using the dip switches (6). The unit has four different battery type settings:

Non-sealed lead-acid batteries (where you can unscrew the lid of the battery and top it up with water): The absorption voltage is 14.8V.

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 specification for gel batteries as laid down by Exide. The absorption voltage is 14.4V.

Gel batteries (U.S. specification): This is the standard U.S. specification for gel batteries. The absorption voltage is 14.1V.

Sealed lead-acid batteries and AGM batteries: These batteries are also charged at an absorption voltage of 14.4V, however with a shorter absorption time.

The ideal absorption time for each battery type is recalculated automatically for each new charging cycle.

Start-Up and Test Procedure

As soon as the unit is connected, it senses the output voltage from the alternator. When the alternator is producing voltage, the alternator-to-battery charger will start up, indicated by a slow flashing of the top green LED. The start-up phase will be about 2 to 3 minutes during which the unit is only working as a passive split charge device.

When the start-up phase is completed, the top green LED (1) will come on constantly, indicating that the unit is now in the constant current phase and is boosting the current into the domestic battery bank. At the same time, the load on the alternator will increase.

The voltage on the domestic battery output will then rise until it reaches the absorption voltage for the selected battery type. After that the output will be kept constant on absorption voltage (14.1V to 14.8V) and the yellow timer LED (2) will come on. The unit’s intelligent software automatically calculates the optimum absorption time (between 1 and 24 hours.)

When the batteries are fully charged, the voltage will be reduced to a constant float voltage (13.6V to 13.8V).

During the boost and the absorption phase the entire charging cycle is suspended for 3 minutes every 20 minutes to provide additional charge capacity for the starter battery.

If, thereafter, the voltage of the domestic battery drops below

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