MEAN WELL NPB-1200 Series High Reliable Ultra Wide Output Range Intelligent Battery Charger Owner’s Manual

MEAN WELL NPB-1200 Series High Reliable Ultra Wide Output Range

Intelligent Battery Charger

Product Specifications

Model| Vboost (Default)| Vfloat (Default)| Charge Voltage Range| Output Current| Output Power| Recommended Battery Capacity
---|---|---|---|---|---|---
NPB-1200-12| 14.4V| 13.8V| 10.5 – 21V| 70A| 1176W| 240 – 800AH
NPB-1200-24| 28.8V| 27.6V| 21 – 42V| 36A| 1209.6W| 120 – 420AH
NPB-1200-48| 57.6V| 55.2V| 42 – 80V| 18A| 1209.6W| 60 – 210AH

FAQ

Frequently Asked Questions

Q: What is the default voltage for Vboost and Vfloat?

A: The default Vboost voltage is 14.4V for NPB-1200-12, 28.8V for NPB-1200-24, and 57.6V for NPB-1200-48. The default Vfloat voltage is 13.8V, 27.6V, and 55.2V respectively.

Q: How can I adjust the charge voltage range?

A: The charge voltage range can be adjusted using the SBP-001 smart battery charging programmer within the specified limits for each model.

Q: What is the recommended battery capacity for each model?

A: The recommended battery capacity ranges from 240 to 800AH for NPB-1200-12, 120 to 420AH for NPB-1200-24, and 60 to 210AH for NPB-1200-48.

Q: Is there a weight specification for the product?

A: The weight of the product is approximately 1.93Kg.

Q: What is the efficiency of the charger?

A: The typical efficiency of the charger is 92% for NPB-1200-12, 93% for NPB-1200-24, and 94% for NPB-1200-48.

Overview

Features

• Auto ranging with ultra-wide charging voltage (10.5~21V, 21~42V, 42~80V; Please refer to page 8 for setting)
• Built-in CANBus protocol for control, setting and monitoring
• Programmable charging curve via SBP-001
• Manual setting for 2/3 stage and 4 built-in charging curves via DIP S.W
• Multiple protections: Short circuit / Over voltage / Over temperature/ Battery under voltage/Battery reverse polarity (No damage)
• Charger OK and Battery Full signal
• Temperature compensation function to prolong battery life (Lead-acid only)
• -30°C ~+70°C wide operating temperature
• Thermal controlled DC fan for noise reduction
• Remote ON/OFF control
• Smart programmer available (Order NO.: SBP-001, sold separately)
• Carry handle accessory available(Order NO.: Carry handle, sold separately
• Comply with 62368-1 + 60335-1/-2-29 dual certification
• Suitable for lead-acid (Pb) and li-ion batteries
• 3 years warranty

Applications

• AGV
• E-Bike, E-Scooter, Camping car, Bus, Specialty vehicles
• Robotic lawn mower
• Washing robot
• Recreation craft, Personal yacht or workboat
• Surveillance system
• Telecommunication base station
• Radio system backup solution
• Equipments or instruments with back-up battery

GTIN CODE

• MW Search: https://www.meanwell.com/serviceGTIN.aspx

Description

NPB-1200 is a miniaturized, versatile, and ultra-wide voltage intelligent charger. It utilizes a fully digital control design with automatic battery voltage detection technology, with five key features including intelligent, versatile, user friendly, safe, and compact. The series have four models with output voltage ranges of 10.5~21V, 21~42V and 42~80V respectively. The charging voltage range of each model is wide enough to cover a variety of different battery voltages and battery chemistries, and there is a built-in intelligent voltage detection charging mode (Note this mode is set to OFF by factory default and is suitable for lithium batteries with BMS only). The NPB-1200 can pair with MEAN WELL’s SBP-001 programmer for digital configuration, such as adjust charging voltage/current, and set charging cycle time to protect battery lifetime. Through the user-friendly DIP S.W. on front panel, user may also directly adjust the 2/3 stage charging, current (50~100%), and select between the 4 types of preset charging curves. In addition, a CANBus communication protocol is built in to meet professional applications, which allows remote controlling and monitoring for the status of the charger.

In terms of safety, it has intelligent detection for proper battery voltage and connection as well as protection from reverse polarity. It passes ITE IEC/EN/UL62368-1 and household appliances EN60335-1/-2-29 dual safety and 3-year warranty to guarantee reliable operation. The NPB-1200 is truly an intelligent, safe, and reliable universal charger with outstanding cost performance.

Model Encoding

SPECIFICATION

OUTPUT

| BOOST CHARGE VOLTAGE(Vboost)(default)| 14.4V| 28.8V| 57.6V
FLOAT CHARGE VOLTAGE(Vfloat)(default)| 13.8V| 27.6V| 55.2V
CHARGE VOLTAGE RANGE Note.3| 10.5 ~ 21V| 21 ~ 42V| 42 ~ 80V
MAX. OUTPUT CURRENT(CC) Note.4| 70A| 36A| 18A
MAX. POWER Note.4| 1176W| 1209.6W| 1209.6W
RECOMMENDED BATTERY CAPACITY (AMP HOURS) Note.5| 240 ~ 800AH| 120 ~ 420AH| 60 ~ 210AH
LEAKAGE CURRENT FROM BATTERY (Typ.)| <1mA

INPUT

| VOLTAGE RANGE Note.6| 90 ~ 264VAC            127 ~ 370VDC
FREQUENCY RANGE| 47 ~ 63Hz
POWER FACTOR (Typ.)| PF>0.98/115VAC, PF>0.95/230VAC at full load
EFFICIENCY (Typ.) Note.7| 92%| 93%| 94%
AC CURRENT (Typ.)| 12A/115VAC             6.5A/230VAC
INRUSH CURRENT (Typ.)| COLD START 50A at 230VAC
LEAKAGE CURRENT| <1mA/240VAC

PROTECTION

| SHORT CIRCUIT Note.8| Protection type : Constant current limiting, charger will shutdown after 5 sec, re-power on to recover
OVER VOLTAGE Note.9| 21.5 ~ 26V| 43 ~ 52V| 82 ~ 100V
Protection type : Shut down and latch off o/p voltage, re-power on to recover
REVERSE POLARITY| Protected internal reverse detection, No damage, re- power on to recover after fault condition is removed
OVER TEMPERATURE| Shut down O/P voltage, recovers automatically after temperature goes down

FUNCTION

| CHARGING STAGE| 2 or 3 stage selectable through DIP S.W on panel
CHARGING PARAMETERS ADJUSTABLE| Programmable: Constant current(CC),Tapper current(TC), Constant voltage(CV) and Float voltage(FV)

can be set through SBP-001 with computer

Manual setting: 4 built-in charging curves adjustable via DIP S.W on panel, Please refer to function manual for more detail
AUTO RANGING FOR CHARGING (Typ.)| Please refer to functin manual for more detail (page 8)
Charging current adjustable 50~100% by via potentiometer on panel (Only for auto ranging mode)
CANBUS INTERFACE| CANBus 2.0B, Can control, Setting and monitoring(V O ,I O ,charging curve, internal temp. and DC output ON/OFF)
CHARGER OK| The TTL signal out, Charger OK = H(4.5 ~ 5.5V) ; Charger failure or protection status =L( -0.5 ~ +0.5V)
BATTERY FULL SIGNAL| The TTL signal out, Battery full = H(4.5 ~ 5.5V ); Charging = L(-0.5 ~ +0.5V)
REMOTE CONTROL| Short : Charger normal work            Open : Charger stop charging
TEMPERATURE COMPENSATION| By external NTC
FAN SPEED CONTROL| Depends on internal temperature

ENVIRONMENT

| WORKING TEMP.| -30 ~ +70℃ (Refer to “Derating Curve”)
WORKING HUMIDITY| 20 ~ 95% RH non-condensing
STORAGE TEMP., HUMIDITY| -40 ~ +85℃, 10 ~ 95% RH non-condensing
TEMP. COEFFICIENT| ±0.05%/℃ (0 ~ 50℃)
VIBRATION| 10 ~ 500Hz, 2G 10min./1cycle, 60min. each along X, Y, Z axes

SAFETY & EMC

(Note 10)

| SAFETY STANDARDS| CB IEC62368-1,IEC60335-1/2-29, Dekra BS EN/EN62368-1,BS EN/EN60335-1/2-29, UL62368-1, EAC TP TC 004 approved
WITHSTAND VOLTAGE| I/P-O/P:3KVAC  I/P-FG:2KVAC  O/P-FG:0.5KVAC
ISOLATION RESISTANCE| I/P-O/P, I/P-FG, O/P-FG:100M Ohms / 500VDC / 25℃/ 70% RH

EMC EMISSION

| Parameter| Standard| Test Level / Note
Conducted| BS EN/EN55032 (CISPR32)| Class B
Radiated| BS EN/EN55032 (CISPR32)| Class A
Harmonic Current| BS EN/EN61000-3-2| Class A
Voltage Flicker| BS EN/EN61000-3-3| —–

EMC IMMUNITY

| Parameter| Standard| Test Level / Note
ESD| BS EN/EN61000-4-2| Level 3, 8KV air ; Level 2, 4KV contact
Radiated| BS EN/EN61000-4-3| Level 2, 3V/m
EFT / Burst| BS EN/EN61000-4-4| Level 2, 1KV
Surge| BS EN/EN61000-4-5| Level 3, 1KV/Line-Line,Level 3, 2KV/Line-Earth
Conducted| BS EN/EN61000-4-6| Level 2, 3Vrms
Magnetic Field| BS EN/EN61000-4-8| Level 1, 1A/m
Voltage Dips and Interruptions| BS EN/EN61000-4-11| >95% dip 0.5 periods, 30% dip 25 periods,

95% interruptions 250 periods

OTHERS

| MTBF| 517.5K hrs min.        Telcordia SR-332 (Bellcore) ; 47.5K hrs min.        MIL-HDBK-217F (25℃)
DIMENSION| 25015867mm (LWH)
PACKING| 1.93Kg; 4pcs/ 10Kg / 1.72CUFT
NOTE|

1. Modification for charger specification may be required for different battery specification. Please contact battery vendor and MEAN WELL for details.

2. All parameters NOT specially mentioned are measured at 230VAC input, rated load and 25°C of ambient temperature.

3. This is the range when programming Vboost or Vfloat by using SBP-001, the smart battery charging programmer.

4. Refer to derating curve.

5. This is MEAN WELL’s suggested range. Please consult your battery manufacturer for their suggestions about maximum charging current limitation.

6. Derating may be needed under low input voltages. Please check the derating curve for more details.

7. The efficiency is measured at 16.8V charge voltage(12V model), 33.6V charge voltage(24V model), 67.2V charge voltage(48V model).

8. This protection mechanism is specified for the case the short circuit occurs after the charger is turned on.

9. Each model incorporates a MCU-controlled dynamic over voltage protection, which is about 125% of boost over Constant Current stage and Constant
   Voltage stage whereas 125% of Vfloat over Float stage.

10. The charger is considered a component which will be installed into a final equipment. All the EMC tests are been executed by mounting the unit on
    a 600mm*900mm metal plate with 1mm of thickness. The final equipment must be re-confirmed that it still meets EMC directives. For guidance on how to perform these EMC tests, please refer to “EMI testing of component power supplies.”
    (as available on https://www.meanwell.com//Upload/PDF/EMI_statement_en.pdf)

11. The ambient temperature derating of 3.5°C/1000m with fanless models and of 5°C/1000m with fan models for operating altitude higher than 2000m(6500ft).

• Product Liability Disclaimer:  For detailed information, please refer to https://www.meanwell.com/serviceDisclaimer.aspx

Block Diagram

Derating Curve

Static Characteristics

Derating Curve

The rated current should change with the output voltage programming accordingly.

Function Manual

Manual setting

2 or 3-stage selectable via DIP S.W on panel

charging curve
2| Charging curve adjustable| 4 built-in charging curves adjustable via DIP S.W
3

Charging curve can be adjustable via DIP S.W on panel

2 stage charging curve

• Suitable for lead-acid batteries (flooded, Gel and AGM) and Li-ion batteries (lithium iron and lithium manganese).

Default 3 stage charging curve

• Suitable for lead-acid batteries (flooded, Gel and AGM) and Li-ion batteries (lithium iron and lithium manganese).

The default curve is programmable, whereas other pre-defined curves can be activated by the means of the DIP S.W; Please refer to the table below and the Mechanical Specification.

Embedded 2 stage charging curve

70A

| 14.4
ON| OFF| Pre-defined, gel battery| 14.0
OFF| ON| Pre-defined, flooded battery| 14.2
ON| ON| Pre-defined, AGM battery,LiFe04| 14.6
DIP SW position| 24V model
2| 3| Description| CC(default)| Vboost
OFF| OFF| Default, programmable|

36A

| 28.8
ON| OFF| Pre-defined, gel battery| 28.0
OFF| ON| Pre-defined, flooded battery| 28.4
ON| ON| Pre-defined, AGM battery,LiFe04| 29.2
DIP SW position| 48V model
2| 3| Description| CC(default)| Vboost
OFF| OFF| Default, programmable|

18A

| 57.6
ON| OFF| Pre-defined, gel battery| 56.0
OFF| ON| Pre-defined, flooded battery| 56.8
ON| ON| Pre-defined, AGM battery,LiFe04| 58.4

Embedded 3 stage charging curve

70A

| 14.4| 13.8
ON| OFF| Pre-defined, gel battery| 14.0| 13.6
OFF| ON| Pre-defined, flooded battery| 14.2| 13.4
ON| ON| Pre-defined, AGM battery,LiFe04| 14.6| 14.0
DIP SW position| 24V model
2| 3| Description| CC(default)| Vboost| Vfloat
OFF| OFF| Default, programmable|

36A

| 28.8| 27.6
ON| OFF| Pre-defined, gel battery| 28.0| 27.2
OFF| ON| Pre-defined, flooded battery| 28.4| 26.8
ON| ON| Pre-defined, AGM battery,LiFe04| 29.2| 28.0
DIP SW position| 48V model
2| 3| Description| CC(default)| Vboost| Vfloat
OFF| OFF| Default, programmable|

18A

| 57.6| 55.2
ON| OFF| Pre-defined, gel battery| 56.0| 54.4
OFF| ON| Pre-defined, flooded battery| 56.8| 53.6
ON| ON| Pre-defined, AGM battery,LiFe04| 58.4| 56.0

Programmable charging curve

Charging Curve can be set via SBP-001 with computer

Step 1: Hardware configuration

Step 2: Connect to software for setting

NPB-1200 pin assigment

NPB-1200 14pins connector (Connector Part No.: HRS DF11-14DS)

| 1| 2| 3| 4| 5| 6| 7| 8| 9| 10| 11| 12| 13| 14
A1| A0| +3.3V| GND| Battery Full| Charger OK| Remote ON-OFF| +12Vaux|

GND-AUX

| CANH| CANL| NTC (RTH+)| NTC (RTH-)

SBP-001 pin assigment

SBP-001

10 pins connector

(Connector Part No.: HRS DF11-10DS)

| 1| 2| 3| 4| 5| 6| 7| 8| 9| 10
UART_RX| UART_TX| PMBUS_D| PMBUS_C| CANH| CANL| 5V| GND| 3.3V| GND

Function Description

SBP-001 is a programmer, particularly for MEAN WELL’s various programmable battery charger models to program the parameters of charging curves, such as Constant current (CC), tapper current(TC), Constant voltage (CV),float voltage (FV),Charging time out and so on,to accommodate the diversified battery specification in industry.With the design accounting for simplicity and convenience, users can easily configure MEAN WELL’s programmable battery chargers with SBP-001 programmer and the computer; all of the setups are able to be finished easily by the means of the specific software.

Note

1. Tapper current(TC) default is 10%, can be fine tuned from 2% to 30% by SBP-001 with computer or CANBus Interface.
2. Please contact MEAN WELL for more details.

Software Interface

Auto Ranging for Charging

Auto Ranging for Charging (Default non-Auto ranging)

Function Description:

• NPB-1200 has built-in auto ranging mode.
  • (Note this mode is set to OFF by factory default and is suitable for lithium batteries with BMS only)
• When operating in auto ranging mode , NPB-1200 will automatically detect the voltage of battery that is connected and adjust charging voltage accordingly. It will not start charging unit appropriate battery voltage is detected.
• While under auto ranging mode, NPB-1200’s built-in MCU will adjust charging voltage. There is no potentiometer for voltage adjustment on the front panel.
• While under auto ranging mode, the charging current can be adjusted between 50~100%.
  • (The charging current can not be adjusted via potentiometer while not operating in auto ranging mode)

When using the auto ranging charging curve function, please pay attention to the following:

1. Default factory setting is OFF via DC output side DIP S.W, Follow steps A1~A6 below to enable the setting.
2. Auto ranging function should use together with Lithium batteries and BMS anagement System).
3. Do not exceed the output voltage and current ranges as specified in the NPB-1200 specifications (please refer to page 2).

Auto Ranging function by DIP S.W Setting

(Please make sure that the battery is lithium battery and must be matched with BMS before using. Auto ranging function is prohibited for non-lithium battery)

Back to non-auto ranging as following:

Auto Derating function

Covered by over temperature protection, auto de-rating function works under operation either in charging curve (2 or 3 stage) or under control by communication protocol(CANBus).

T1(Typ.): Maximum ambient temperature of 100% output current.
T2(Typ.): T1+5℃.

CANBus communication interface

CANBus 2.0B version, Can control, setting and monitoring that including output charging voltage, output charging current, internal temperature and DC output ON/OFF……and so on, please refer to the user manual for more details.

CANBus commend list

(format: value, F=0.01)

0x0030| IOUT_SET| R/W| 2| Output current setting

(format: value, F=0.01)

0x0040| FAULT_STATUS| R| 2| Abnormal status

0x0050

| READ_VIN

(NPB-450/750

Does not support)

|

R

|

2

| Input voltage read value

(format: value, F=0.1)

0x0060| READ_VOUT| R| 2| Output voltage read value

(format: value, F=0.01)

0x0061| READ_IOUT| R| 2| Output current read value

(format: value, F=0.01)

0x0062| READ_ TEMPERATURE_1| R| 2| Internal ambient temperature

(format: value, F=0.1)

0x0080| MFR_ID_B0B5| R| 6| Manufacturer’s name
0x0081| MFR_ID_B6B11| R| 6| Manufacturer’s name
0x0082| MFR_MODEL_B0B5| R| 6| Manufacturer’s model name
---|---|---|---|---
0x0083| MFR_MODEL_B6B11| R| 6| Manufacturer’s model name
0x0084| MFR_REVISION_B0B5| R| 6| Firmware revision
0x0085| MFR_LOCATION_B0B2| R/W| 3| Manufacturer’s factory location
0x0086| MFR_DATE_B0B5| R/W| 6| Manufacturer date
0x0087| MFR_SERIAL_B0B5| R/W| 6| Product serial number
0x0088| MFR_SERIAL_B6B11| R/W| 6| Product serial number
0x00B0| CURVE_CC| R/W| 2| Constant current setting of charge curve

(format: value, F=0.01)

0x00B1| CURVE_CV| R/W| 2| Constant voltage setting of charge curve (format: value, F=0.01)
0x00B2| CURVE_FV| R/W| 2| Floating voltage setting of charge curve

(format: value, F=0.01)

0x00B3| CURVE_TC| R/W| 2| Taper current setting value of charging curve

(format: value, F=0.01)

0x00B4| CURVE_CONFIG| R/W| 2| Configuration setting of charge curve
0x00B5| CURVE_CC_TIMEOUT| R/W| 2| CC charge timeout setting of charging curve
0x00B6| CURVE_CV_TIMEOUT| R/W| 2| CV charge timeout setting of charging curve
0x00B7| CURVE_FV_TIMEOUT| R/W| 2| FV charge timeout setting of charging curve
0x00B8| CHG_STATUS| R| 2| Charging status reporting
0x00B9| CHG_RST_VBAT| R/W| 2| Reset the voltage point of the charging curve after the battery is fully charged
0x00C0| SCALING_FACTOR| R| 2| Scaling ratio
0x00C1| SYSTEM_STATUS| R| 2| System status
0x00C2| SYSTEM_CONFIG| R/W| 2| System configuration

Charger OK Signal

Charger OK signal is a TTL level signal.
The maximum sourcing current is 10mA.

Battery Full Signal

Battery full signal is a TTL level signal.
The maximum sourcing current is 10mA.

Remote ON-OFF Control

The NPB-1200 can be turned ON/OFF by using the “Remote Control” function.

The charger is shipped, by factory default, with Remote ON-OFF(pin 7) and +12Vaux (pin 8) shorted by connector.

Temperature compensation(3 stage only)

• Temperature compensation function to prolong battery life for lead-acid batteries. Temperature compensation range is 0 ~ 40℃.
• The battery temperature sensor comes along with the charger can be connected to the unit to allow temperature compensation of the charging voltage.
• If the sensor is not used, the charger works normally.

DC Output Side LED Indicators & Corresponding Signal at Function Pins

Mechanical Specification

Intelligent Battery Charger model

DIP S.W

Control Pin No. Assignment: HRS DF11-14DS or equivalent

Connector Pin No. Assignment: HRS DF11-14DS or equivalent

HRS DF11-14DS

or equivalent

|

HRS DF11-**SC

or equivalent

2| A0
3| +3.3V
4| GND(Signal)
5| Battery Full
6| Charger OK
7| Remote ON-OFF
8| +12Vaux
9,10| GND-AUX
11| CANH
12| CANL
13| NTC(RTH+)
14| NTC(RTH-)

LED Status Table

Pin4.(Note.1)
2| A0| CANBus interface address line(A0). Referenced to GND(Signal) Pin4.(Note.1)
3| +3.3V| +3.3V voltage output, referance to GND(pin 4).
4| GND(Signal)| CANBus interface address lines GND.

5

|

Battery Full

| Battery Full Signal, referenced to GND-AUX(Pin 9 & 10).

The Signal is a TTL level signal. The maximum sourcing current is 10mA and only for output.(Note.2) Low (-0.5 ~ 0.5V) : When the battery is charging.

High (4.5 ~ 5.5V) : When the battery is full.

6

|

Charger OK

| Charger OK Signal, referenced to GND-AUX(Pin 9 & 10).

The Signal is a TTL level signal. The maximum sourcing current is 10mA and only for output.(Note.2) Low (-0.5 ~ 0.5V) : When the charger fails or the protect function is activating.

High (4.5 ~ 5.5V) : When the charger is working properly.

7

| Remote ON-OFF| Remote charger ON/OFF Function.

The charger can turn the output ON/OFF by dry contact between Remote ON-OFF and +12V-AUX.(Note.2)

Short (10.8 ~ 13.2V) : Charger ON ; Open (-0.5 ~ 0.5V) : Charger OFF ; The maximum input voltage is 13.2V.

8| +12Vaux| It is controlled by the Remote ON-OFF control.
9,10| GND-AUX| The signal return is isolated from the output terminal. (+V & -V)
11| CANH| For CANBus model: Data line used in CANBus interface. (Note.2).
12| CANL| For CANBus model: Data line used in CANBus interface. (Note.2).
13| NTC(RTH+)| Temperature sensor(NTC, 5KOhm) comes along with the charger can be connected to the unit to allow temperature

compensation of the charging voltage for lead-acid batteries. Temperature compensation range is 0 ~ 40℃(3 stage only).

14| NTC(RTH-)

Note1: Non-isolated signal, referenced to [GND(signal)].
Note2: Isolated signal, referenced to GND-AUX

Accessory List

NTC Sensor and Remote Control mating along with NPB-1200 (Standard accessory)

Connection Diagram

Carry handle (Optional accessory, battery charger and pull handle should be ordered seperately)

Handle

Foot pad

INSTALLATION MANUAL

• Please refer to: http://www.meanwell.com/manual.html

User’s Manual

Documents / Resources

| MEAN WELL NPB-1200 Series High Reliable Ultra Wide Output Range Intelligent Battery Charger [pdf] Owner's Manual
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