SmartGen BAC2410BST Battery Charger User Manual

Company Information

SmartGen Technology Co., Ltd.

Address: No.28 Jinsuo Road, Zhengzhou City, Henan Province, P. R. China

Tel: +86-371-67988888 / +86-371-67981888 / +86-371-67992951 / +86-371-67981000 (overseas)

Fax: +86-371-67992952

Web: www.smartgen.com.cn, www.smartgen.cn

Email: sales@smartgen.cn

Copyright © SmartGen Technology. All rights reserved.

Software Version History

1 Overview

The BAC2410BST Battery Charger is an advanced switching power supply device designed specifically for the charging characteristics of lead-acid engine starter batteries. It is suitable for long-term supplemental (floating) charging and for 24V battery packs.

2 Performance and Characteristics

• Employs a switching power supply structure, offering a wide input voltage range, compact dimensions, light weight, and high efficiency.
• Features a two-stage or three-stage charging method, selectable based on needs (Three-stage: BOOST and B- terminals short-circuited; Two-stage: BOOST terminal is left open). Both methods are optimized for battery charging characteristics to prevent overcharging and extend battery life.
• Includes a built-in PFC (Power Factor Correction) circuit, achieving a power factor above 0.99.
• Equipped with a built-in current protective circuit for protection against overcurrent, short circuit, or reverse connection, with automatic recovery when conditions are resolved.
• Suitable for charging 24V battery packs with a rated charging current of 10A.
• External LED status indicators: Green indicates full charge; Red indicates charging.

3 Charging Principle

Three-Stage Charging

This method follows the battery's charging characteristics:

• Stage 1 (Bulk Charging): Constant Current mode. When battery terminal voltage is low, the charger delivers a high current (rated 10.0A) to rapidly increase battery power. The red indicator is typically lit.
• Stage 2 (Absorption Mode): After bulk charging, the battery voltage rises to the absorption voltage. The charger maintains a constant voltage output, while the charging current gradually decreases. The red indicator remains lit.
• Stage 3 (Float Charging): Once the battery is nearly fully charged, the output voltage switches to the float voltage (27.6V), and the charging current drops below the float current (1.0A). The red indicator extinguishes, and the green indicator illuminates. The charger then provides minimal current to offset the battery's self-discharge, ensuring the battery remains fully charged without damage and preserving its lifespan.

Diagram Description (Fig.1 Three-stage Charging Curve): The diagram shows voltage and current curves over time. The voltage curve starts at a lower level, rises to a constant current phase, then transitions to a constant voltage phase, and finally settles at a float voltage. The current curve starts high (rated charging current), decreases during absorption, and becomes very low during float charging. Green LED indicates fully charged, Red LED indicates being charged.

Two-Stage Charging

This method also follows battery charging characteristics:

• Stage 1 (Constant Current): When the battery terminal voltage is below a preset value, the charger operates in constant current mode.
• Stage 2 (Absorption Mode): When the battery terminal voltage exceeds the preset value, the charging current gradually decreases as the voltage increases. When the current drops below 1.0A, the terminal voltage increases to the preset constant voltage. At this point, the battery is considered nearly fully charged. The red indicator turns off, and the green indicator turns on. The charger then supplies current to counteract self-discharge, maintaining the full charge status and battery life.

Diagram Description (Fig.2 Two-stage Charging Curve): Similar to the three-stage curve, but omits the distinct float stage. It shows a constant current phase followed by a constant voltage phase where current decreases.

4 Parameters Configuration

Technical Parameters

Efficiency Curve

Diagram Description (Fig.3 Efficiency Curve): The graph plots efficiency (%) against input voltage (V) for a 10A charging current. It shows efficiency increasing with input voltage, reaching approximately 93% at 260V input.

5 Operation

Diagram Description (Fig.4 BAC2410BST MASK): The diagram shows the front panel of the charger with input/output terminals and indicators. Terminals are labeled L, N, PE, BOOST, B-, B+. Indicators are labeled FULL CHARGED (Green LED) and CHARGING (Red LED).

Connection Description

Notes:

• Due to the internal diode and current-limiting circuit, the charger can be used with a charging generator without needing to disconnect during cranking.
• When used with a genset, significant charging current can cause voltage drop on the charging wire. It is recommended to connect the charging wire directly to the battery terminals separately to avoid affecting measurement precision.

6 Case Dimensions

Diagram Description (Fig.5 BAC2410BST Case Dimension): The diagram provides the physical dimensions of the charger. The overall dimensions are approximately 210mm (length) x 131mm (width) x 55mm (height). Specific mounting hole details are also indicated.