STERLING POWER PRODUCTS

STERLING POWER PRODUCTS ALTERNATOR - to - BATTERY CHARGER Advnced chrging technology AB0 AB0 AB0 AB0 Pro Digitl REMOTE CTROL (OPTI) Bttery-Bttery Chrger on/off. V timer 0. A min lrm light Alrm shutdown System disengged Low input voltge System o.k. Sterling power products ORDER NO: ABRC CE Instlltions Instructions & mnul Instlltions- und Bedienungsnleitung

Advnced Digitl Voltge Amplifier 0 All yellow circles with numers on them re referenced to the instlltion drwing on pge Wht does it do: down y Exide for its gel tteries. Bsiclly it is.. volts for out This unit is comined split chrge diode system nd voltge mplifier. The unit comprises of one lterntor input nd two ttery nk outputs. 0- hourss, regrdless of the stte of the tteries, then it drops to flot GEL/ U.S.A. SPECK. For some reson the gel is different in the The output mrked strter ttery is stright chnnel through diode U.S.A. nd they hve sked for lower chrge voltge of. volts t which hs no oost function s it is the chnnel tht must e connected to different time setting which then drops to flot. the ot/vehicle engine system, most vehicle E.C.U. systems cnnot del A.G.M./seled. This hs chrger voltge of out. volts with with high input voltge ecuse this would set off lrms in the E.C.U. system (engine electronic mngement system). The ssumption we re softwre timed cycle which then drops to flot t out. volts. Most so-clled.g.m. tteries re in fct only seled led cid. mking is tht the chnnel mrked domestic ttery is independent from the engine strter system nd tht none of the engine mngement system is connected to it ( common negtive is lright nd essentil for the Alwys rememer tht fst chrging costs wter, so if the ttery is seled nd you cnnot top up the wter then do not use it for fst chrging. Open led cid tteries re est for domestic systems. system to work). The se opertion of this system is very stright My dvice is to use the open led cid tteries wherever possile s they forwrd: Simply n lterntor with split chrger diode system with two re lso the lowest cost-void gel y fr (the worst type of tteries re outputs. seled/.g.m.). Instll the unit s close s possile to the lterntor nd The clever prt: tteries (tking into ccount the ove requirements). If you need to fit it First of ll, let me explin why the most effective wy to get the most in n enclosed engine room (e.g. in smll ycht where the engine room out of your lterntor system is to use n Advnced lterntor regultor (see the Sterling universl digitl lterntor regultor rnge). is fully enclosed with sound proofing - where I come from this is clled n oven :-), then try to instll ny equipment s low s possile, idelly However, this is not lwys esy to fit, nd with some modern vehicle outside the engine room ner to the ttery ox. (On seprte note: engine mngement systems nd wrrntees it my lso not e possile to Alwys rememer tht the only ir-cooled item in the engine room is your fit. There re two wys to get the mximum out of n lterntor: Either lterntor which mens tht if you hve totlly seled room you should increse the voltge coming out of the lterntor (fit n dvnced not e surprised if you go through lterntors on regulr sis. If the lterntor regultor) or pull the lterntor s voltge down so tht the engine room is seled, then put vent tue from outside to the ck of the lterntor s own regultor works t full performnce. Both of the ove lterntor. This will enle the lterntor to suck ir through the ck to options work s fr s mximising the lterntor output is concerned. cool itself nd you will not experience ny lterntor prolems.) However, with the second option (pulling the lterntor voltge down) To instll the unit: you would find tht even though you hve mximised the lterntor s ) Connect the min lterntor output (B) to the centre stud mrked performnce s intended, you hve lso ended up with voltge nd lterntor input nd then simply connect the other two studs, one to the current which re solutely useless for ttery chrging purposes. A engine ttery nd one to the domestic ttery. Plese ensure tht the stndrd lterntor is set t out volts. So if we pull the voltge down cle used cn crry the full current of the lterntor. It is lwys est to to volts to mximise the lterntor s current, then volts is no good hve x plus the cpility to reduce voltge drops, i.e. if you hve 0 for chrging tteries fst. (Clm down, you hven t wsted your money mp lterntor, then use 0 mp cle. on this thing :-) ) The unit hs smller negtive wire which requires 0 mp cle nd The solution: If you pulled the voltge down nd ended up with useless should e connected directly to the lterntor negtive t the lterntor voltge s descried ove, ut therefter mplified the voltge from to cse or negtive stud. This wire is lot smller thn the lterntor cle. volts nd fitted -step digitl control system (s used y our which my sound confusing s you would think tht if you hd 00 mp ttery chrgers nd dvnced regultors), then you would hve the lterntor with 00 mp cle on the positive, then you would require enefits of pulling the lterntor down s well s the enefits of the 00 mp cle on the negtive (don t sk s it would tke ook to dvnced regultor - ll in one ox. explin, ut just trust me tht the smller cle is lright). The worry: The only concern with the ove-detiled system is tht it ) If you lredy hve split chrger diode, then the three positive cles my hve negtive effects on the engine strt ttery which t the end of re lredy there. Simply replce the diode with this unit nd connect the the dy is the most importnt ttery. We hve therefore incorported two negtive. see the sic instlltion drwing softwre functions into our design which will ensure tht the ttery For the sic instlltion tht s it, jo done. Simply switch on the remins fully chrged. The mplifier is not used for the first. minutes engine nd the softwre will fire up the unit, nd wy it goes. (the top green light will flsh to show tht the system is working) nd Extr wiring to enhnce the performnce of the unit even though the softwre is in control, it is not doing nything in order to In order to improve the performnce of this unit we hve dded extr ensure tht mximum mount of mps re fed into the strter ttery fetures which ll help, ut re not required for the unit to work. which in turn llows the ttery to recover in the fstest time possile. The mplified section is then switched off every minutes (for nother. Bttery temp: Simply connect one of the enclosed temperture minutes) to ensure tht the engine strt ttery is lright. The unit sensors to ttery terminl post (negtive or positive) nd to the two (when on mximum mplifiction) hs the ility to pull the lterntor smll terminls mrked ttery temp nd the system will pick up the het down to 0 volts which would result in the loss of the engine strt system. through the led. The output voltge will e reduced in ccordnce with Similrly, if you were to put hevy lod on the engine system (such s the mnufcturers ttery chrging temperture curves nd in the event of putting on the hedlights of vehicle), then you would lose the engine the ttery temperture incresing due to ttery filure nd the ttery which oviously is not cceptle. In order to overcome this temperture reching in excess of 0 deg c (mjor prolem), the unit will prolem, we hve therefore dded low volts regultor on the vehicle switch off the mplifier. (However, the stright through pth from the ttery so tht it will never go elow volts. Even when the lterntor is lterntor is still connected which mens tht if the prolem which hs completely exhusted, the engine system will lwys hve power priority, cused the tteries to overhet is the filure of your stndrd despite the fct tht the other side is much more powerful. As you cn see regultor in the lterntor, we will give wrning, ut won t e le from the grphs of n ctul test run, the vehicle s ttery continues to to stop it). chrge even when the oost is working t full power. Alterntor high temp disengge: 0 This is nother temp sensor Instlltion: (supplied) tht should e connected to your lterntor output post (B) The instlltion process is very esy. If you lredy hve split diode, nd which will disengge the mplifier in the event of the lterntor then it s simple; if not, just follow the instructions. Instll the unit in reching 00 deg c. This will not set off n udile lrm, ut simply cool, dry nd well-ventilted position s it is not wterproof, nd plese indicte the prolem with l.e.d. The remote (if fitted) will then show mke sure not to fit it in ox s the het produced y the unit must e when the lterntor hs cooled down enough for the system to got rid of. utomticlly re-engge nd crry on its work. Progrm the ttery type into the unit: Go to the ttery type, Domestic sense: The unit comes s stndrd with the fcility to sense progrm the dip switches on the unit nd set the ttery type. There re three min types of ttery: ll the control voltges t the unit. However, if you would like to sense the N SEALED LEAD ACID: (or seled led cid where you cn voltge t the domestic ttery directly in order to overcome the voltge unscrew the lid of the ttery nd top it up with wter): This type of drops in the cle run drops, then simply connect cle from the ttery hs long life nd is the est for fst chrging (mx voltge.). domestic sense connection directly to the domestic ttery GEL / EXIDE SPECIFICATI: This is the new specifiction lid Strter solenoid: Some lterntors cnnot work if there is no voltge

on their min B terminl which fires up the lterntor. This is esy to see switching on the switch numer on the regultion voltge, the engine ecuse when you fit spit chrge diode there is no feed on the B which ttery is dropped from to. volts which in turn improves the oost in turn mens tht the engine will strt, ut tht the lterntor my not effect from the unit. Wrning: Do not do this unless you hve the ovedescried prolem s this could result in low engine strt ttery work. If this is the cse, the wy to overcome this is to use the strter solenoid feed. This is simple feed tht connects the terminl on the performnce. strter motor nd which only ecomes live when the strter motor endix Strt-up nd test procedure: is engged (i.e. the first two seconds of hving the ignition key fully on). As soon s the unit is connected it senses the output voltge from the Then when the strter is disengged, the point ecomes ded. Wht lterntor, so when the lterntor strts up, there will e slow flshing of ctully hppens is tht volt feed is sent to the lterntor B terminl the top green l.e.d. This confirms tht the unit is working (even though it for the strter durtion (which is enough) nd tht then fires up the remins inctive for the first. minutes to llow little time for the lterntor. After this the lterntor then looks fter itself. engine ttery to recover). After this time period the green light will Remote control kit: An optionl extr with this unit is discontinue flshing nd disply continuous green insted. The chnces the remote control kit which comes complete with remote disply nd re tht the engine lod will increse. The system is then on constnt two s plus two 0 mp cle link wires. current nd the unit should e oosting the current into the domestic ttery nk. This high current will continue for out minutes fter The two shunts mesure oth the domestic nd the engine ttery which it will stop for. minutes in order to ensure tht the engine ttery current, nd the softwre works out the lterntor current. The remote is lright. Once the domestic ttery reches. volts, the trimer l.e.d. mesures things such s voltges nd tempertures, nd in the event of will come on nd the high chrge rte will continue for the time from prolem it does not only disply wht the prolem is, ut lso wht needs switch on to. volts x 0, with minimum of one hour nd mximum to e done out it. of six hours. The rest periods every minutes for. minutes re lso Instll shunts: for remote pnel ( optionl extr ) tken into ccount during this period The remote kit comes with the two shunts, plus two hevy connector If on strt-up nothing hppens, then: cles. It is very importnt tht the smll sensor cles you need to fit re ) Test the lterntor voltge. It should e out. volts, ut if it isn t connected the right wy round s otherwise the current redings will not then the unit is t fult. ) If the lterntor voltge is elow 0 volts, then the lterntor is either e correct. Look t the p.c. drwing. with the nd mrkings nd defective, or it my not e working ecuse it needs volts on the B connect the sensor cles to the shunt in the correct position s per the terminl for it to work successfully. To check if this is the cse, simply drwing on the full instlltion drwing, use low current - mp cle short out etween the lterntor connection nd one of the ttery Shunt type djustments: Internl djustments (not required s connections in order to set volts up the lterntor cle. If the lterntor stndrd). This unit comes set up for the stndrd Sterling fires up nd everything works, then look t the extr terminl mrked Ing ( mv = mp), however, it cn e re-progrmmed to ccept 00 mp feed, nd connect this to the strter motor solenoid enggement s per the shunt (0. mv = mp). Mke sure tht you do not mke djustments instructions. This will shoot volts up the line to fire up the lterntor. unless you fully understnd how to. If in dout, plese cll us for help. ) The unit needs out. volts on the lterntor to work s filure to rech this voltge will prevent the mplifier from coming on line. Low lterntor regultor djustment: (stndrd set switch off) However, the sic split chrge diode should still e operting. Most regultors come s stndrd etween out. nd. volts. If ) If there re volts going into the unit nd only. or less coming the stndrd regultor is not within its limits nd hs low voltge out, then the diodes hve filed nd the unit needs to e repired. performnce of elow., the unit my not work s well s it could. By Optionl Extr Remote control kit includes prts: see pge Remote Pnel pre mde cle pre mde cle Advnced Digitl Split Chrge Alterntor Voltge Amplifier Screen Min Eng set up temp Dom.v 0A Alt.v 0A System trip System Disengged Low voltge wrning System within limits Sterling power products Screen: Push utton mrked Min. This is the min screen nd the one it is est to leve the unit on. It shows the domestic ttery voltge nd current s well s the lterntor output current nd voltge Screen: Push utton mrked Eng. This shows the engine ttery voltge nd current. It lso shows the time clcultion for the high chrge rte nd the count down to the flot chrge. Screen : Push utton mrked Setup : There re two screens on this utton. Push once for screen, then once gin for screen. Screen shows the system setup, e.g the system is v system nd the ttery type selector is for wet (conventionl led cid). This refers to the domestic ttery only. Screen : Push utton mrked Setup : There re two screens on this utton. Screen shows the effective oost eing delivered t this time nd rnges from 0% (during the rest periods nd on flot) to 00% when system on full power. Screen : Push utton mrked Temp : There re x screens on this utton. Push once for screen, then gin for screen. Screen shows the lterntor temp nd the domestic ttery temp, if the temperture sensors re not fitted it will defult to 0 deg c Screen : Push utton mrked Temp : There re two screens on this utton. Push once for screen, then gin for screen. Screen shows the ox het sink tempertures. LHS stnds for left hnd side. Guess wht RHS stnds for :-) Do not expect these to e the sme temperture. on/off lrm light CE on/off: This switches off the unit oost spect, ut cnnot prevent the stndrd diode splitting from working. The monitoring functions remin on, nd the only wy to know if the unit is switched off is y checking tht the system within limits (l.e.d.) is off nd tht the oost off is on screen. Alrm: This mutes the lrm system. Bck ground light: This switches the ckground light on nd off. Dom.v 0A Alt.v 0A Strt. A Timer: m System set:v Bt Type : Wet Alt Controller Power % Bost Alt Temp 0C Bt Temp 0C Cse LHS C Cse RHS C

CSTANT CURRENT slow flsh unit in-ctive TIMER ACTIVATED FLOAT/CSTANT V LOW BATTERY VOLTS HIGH BATTERY TRIP/V BATTERY TYPE HIGH ALT TRIP HIGH ALT TEMP DISENG HEAT SINK R.H.SIDE HEAT SINK L.H.SIDE Green High Chrge Rte On: (top L.E.D. ) This should e on from strt-up (slow flsh shows unit is on, ut on rest mode, for the first. mins on strt-up nd every 0 minutes or so therefter, see grph ) nd shows tht the lterntor should e working t its mximum. It should remin on until the green flot comes on nd this shows tht the high chrge rte is complete. Yellow Timer Activted: This comes on when the voltge reches out. - volts (x for v), nd depending on how long it took to come on, will dictte how long the timing cycle will remin on. The softwre will clculte the timing for the high chrge rte. This will vry from - hours nd the time will e displyed on the remote pnel nd count down. This light will remin on until the high chrge rte is over, nd will go out t the sme time s the high chrge rte etween - hrs fter ctivtion. Green Flot Mode: This indictes tht ll the high chrge cycles re now over nd should remin on fter ll the high chrge lights re out. The system is now running t stndrd chrge rte only (out volts) regulted on the ttery. Ornge Low Voltge Wrning: This is simply sys tht there is low voltge t the min ttery nk nd hs no ctive function. For informtion only; usully indictes defective lterntor. Red Dul Informtion L.E.D: This L.E.D. Hs two functions nd s such hs two disply modes. flshing = high temp trip nd l.e.d. on permnent = high ttery voltge trip Tri Coloured L.E.D: This simply displys the ttery type tht the processor hs een set to. This is tri-coloured l.e.d. Yellow = open led cid, Green = gel /seled led cid. Red = A.G.M.. Red High Alterntor voltge trip: This will wrn you nd switch off the oost section. This mens tht your lterntor s own regultor hs filed nd tht the lterntor will now oil nd destroy your tteries. There is simply nothing we cn do out this, except wrn you. Plese tke this wrning very seriously nd stop your engine s soon s possile. Remove the lterntor input cle, then continue your journey nd hve the lterntor repired. Yellow: System disengged, this refers to the oost section eing dectivted for the following resons: The lterntor temperture sensor hs exceeded 0 deg c nd hs utomticlly disengged the unit to llow the lterntor to cool down, there is high temp on the het sink, or there is high temperture on the ttery temp sensor. It will reset once the sfety prmeter tht cused the prolem hs een reduced. Red : This gives simple wrning tht the product is overheting. In this cse the oost section will switch off nd should reduce the prolem. However, we cnnot prevent the unit continuing to overhet if it hs een plced in d plce such s seled ox with no ventiltion. If this high temperture is not ddressed y incresing the cooling effect, ie y moving the unit to cooler plce, then it could result in the filure of the unit. Red: sme s ove: Wht do I expect to see from this unit nd why? Position : The interesting point here is tht this is the mgic point, the point where The elow test ws set up nd monitored nd is s close s possile s to wht hppens the domestic ttery voltge exceeds the lterntor input voltge. This is wht the on the verge split chrger system, the engine ttery is 00 mp hr stndrd led process is ll out. cid, nd the domestic ttery is x 00 mp hr stndrd led cid. The engine ttery The steps on the grphs show the unit oosting every minutes, then resting for. ws dischrger to volts ( out 0 engine strts ) nd the domestic nk to out minutes. An exmple of this is the time period etween nd.wht you cn see volts ( will no longer run n inverter nd is out 0% empty. The lterntor used is here is tht y switching off the mplifier (to help the engine ttery chrger more), Bosch 0 mp with stndrd. volt ( vrile ) regultor. the unit ttery type is the engine ttery voltge curve increses during tht step shown t point which progrmmed to open led cid. results in extr current going into the engine ttery t position. The current There re x grphs, one is the current into the tteries, nd the other is vrious reflection of this process is reflected in the other grph mrked the current grph. voltges on the system The current grph shows the current flow into the engine strt ttery nd the domestic System voltge grph: system. The effect of the mplifier cn e clerly seen when the unit switches off for its The key points to pick up on here re:. minutes rest cycle. The current drops from position = mps to position = The yellow trce (lterntor voltge into the unit) clerly shows tht the system is out 0 mps, 00% difference. At the sme time you cn see extr going into the doing its jo. It is designed to pull this voltge down little to enle the stndrd strter ttery which clerly chrges through the whole exercise. lterntor regultor to produce its full current. You cn clerly see tht on position on On completion the unit switches off, nd the process continues s conventionl split the voltge curve the voltge is pulled down to position. The result in current chnge chrger system 0, if however the domestic ttery flls elow volts, the system is from position - which is out 0 mps improvement nd good will uto restrt nd continue the process gin. increse in current. Shows tht the engine ttery is full nd tking no more current..00.0.00.0 volts Engine ttery nk, domestic ttery nk, nd lterntor voltge curves Volts 0 L.E.D. informtion nd lrms Unit expecttions lterntor input voltge strter ttery voltge domestic ttery voltge 0.00 TIME min. time in mins.0 0 0 0 0 0 0 0 0 0 0 0.0000 0.00 0 0.00 0 0.00 0 Domestic ttery nk current curve, with engine ttery nk current curve domestic ttery current strter ttery nk current 0.00 0 0.00 0 0.00 0 mps Amps 0.00 0 0.00 0 0.00 0 0.0000 T im e m in. 0 0 time in mins 0 0

Full System wiring (including optionl remote kit if used Kit prts in green ) Engine ttery current ( optionl remote kit ) This unit comes set up for the stndrd ( mv = mp ). however it cn e re-progrmed to ccept 00 mp shunt 0. mv = mp Low lterntor regultor voltge djustment, this should only e used if the lterntors stndrd voltge regultor is set elow. volts. Do not use unless this is the cse. switch, switch on, switch is not in use Remote control nd informtion pnel ( optionl remote kit ) Power Mngement Advnced Digitl Split Chrge Alterntor with Power Amplifier on/off AMP Hr Counter Defult volts eep. v m Pos lrm Bt.v Timer Screen Alt mps.v m /hrs light Help System Amps Volts set up System Trip System Disengged Amp temp Low voltge wrning hr System Within Limits Sterling power products engine lterntor CE Left Hnd Side fn temp sensor 0 0 mp fuse fuse Right Hnd Side fn Domestic ttery current ( optionl remote kit ) Engine strter key solonoid Strter motor OPEN LEAD ACID GEL- BATTERIES (EXIDE SPECIFICATI) SEALED LEAD ACID & AGM GEL & AGM (USA SPECIFICATI) ENGINE STARTER BATTERY LED COLOUR YELLOW GREEN GREEN-YELLOW GREEN FLASHING FOR SEC. MAX. CHARGING.V / 0 C.V / 0 C.V / 0 C.V / 0 C ABSORBTI TIME - HRS. 0 - HRS. - HRS. - 0 HRS. FLOATING.V / 0 C.V / 0 C.V / 0 C.V / 0 C Bttery temperture sensor cle ( supplied ) ENSURE ALL NEGS ARE COMM Alterntor temperture sensor cle ( supplied ) temp sensor DOMESTIC BATTERY SYSTEM

Bsic wiring System wiring engine lterntor 0 mp fuse fuse fn Left Hnd Side fn Right Hnd Side WHAT CABLE TO USE IN mm sq A chrger or inverter up to cle run distnce 0-. mtr. - mtr 0- mps mm sq 0 mm sq - mps mm sq mm sq - mps mm sq mm sq - mps mm sq 0 mm sq - 0 mps 0 mm sq 0 mm sq 0-0 mps 0 mm sq 0 mm sq Plese note tht if there is prolem otining for exmple 0 mm sq cle, simply Use x 0 mm sq, or x mm sq, the cle is simply copper, nd ll you require Is the copper, it does not mtter if it is one cle or 0 cles s long s the squre OPEN LEAD ACID LED COLOUR YELLOW MAX. CHARGING.V / 0 C ABSORBTI TIME - HRS. FLOATING.V / 0 C GEL- BATTERIES (EXIDE SPECIFICATI) GREEN.V / 0 C 0 - HRS..V / 0 C SEALED LEAD ACID & AGM GREEN-YELLOW.V / 0 C - HRS..V / 0 C GEL & AGM (USA SPECIFICATI) GREEN FLASHING FOR SEC..V / 0 C - 0 HRS..V / 0 C ENGINE STARTER BATTERY ENSURE ALL NEGS ARE COMM DOMESTIC BATTERY SYSTEM