BATTERY: INDUSTRIAL CHARGER & PROGRAMMABLE POWER SOURCE

With the democratization of mobile devices, the drop of manufacturing cost of batteries, as well as the growing awareness on environmental topics issues, the technology of batteries and chargers has witnessed a tremendous breakthrough in the past few decades; numerous of new batteries have seen the light of day, and innovative charger applications are born as accompaniment.


From Electric Vehicle Charging (EV Charging) infrastructure to Energy Storage System (ESS), the modern chargers are utilized in numerous different sectors nowadays and are pushing the society further towards the more sustainable and renewable energy options.

HOW CHARGER IS DIFFERENT FROM REGULAR POWER SOURCE

While common Power Supplies are designed to provide a fixed and constant DC voltage, chargers require a more complex design with different charging phases to assure the longevity of batteries and safety during operation.

To meet the specific charging needs of different types of batteries, industrial chargers are generally designed with several charging phases, including principally a boost voltage-constant current phase, a constant voltage phase, and a float voltage phase.

More advanced industrial chargers use a microcontroller (MCU) design, which detects the charging status of the connected batteries and allows further adjustment between different charging phases.

Nevertheless, it does not mean that chargers are the only option for charging applications nowadays. Advanced technology in power supplies has made it possible to adapt a programmable power supply, with adjustable voltage and current, to the specific charging demands in the field too.

 

HOW TO CHOOSE YOUR CHARGER

Choosing the adequate DC power source for the battery is critical if one wishes to maintain the battery’s performance. In the following paragraphs, we will be listing down a few criteria which are considered essential when it comes to the selection of proper chargers for the system.

 

A. Battery Charging Profile

Each battery type has its own specific charging needs and requirements. These requirements are normally defined by the battery manufacturer and listed in their specification. Hence it is important to start by identifying the battery charging profile before further diving into choosing the suitable charger. For the 2 most popular battery types used, we listed 2 example charging curves below:

 

  • Lead-Acid Battery requires chargers with minimum 3 charging stages. 
lead acid battery stage 1

Image 1: Three Stages for Lead-Acid Battery

  • Lithium-based Battery requires generally chargers with 2 charging stages: first with constant current, followed by constant voltage.
lead acid battery stage 2

Image 2: Two stages for Lithium-based battery (LiFeP04, LiCoO2)

For more information read our “Lead-acid and lithium battery charging” article.

For more information about selecting the right charger for your battery please refer to our  “Selecting a charger from your battery” article.

Tip: MEAN WELL offers a Smart Battery Charging Programmer (SBP-001) which allows users to configure via a user-friendly interface, the charging curve of selected MEAN WELL chargers and power supplies (e.g. Intelligent RCB-1600 charger, HEP-1000 for Harsh environment, ENC…etc.). With SBP-001 programmer, the user can set the output current and voltage to further simulate the charging curve for different batteries.

Intelligent Charger DBU-320

Image 3: Intelligent Charger DBU-3200, configurated via SBP-001 and its user-friendly interface (Click to download)

B. Regulations

According to International Electrotechnical Commission (IEC), numerous regulation standards exist for the purpose of ensuring safety, efficiency, reliability, and interoperability of electrical, electronic, and information technologies; depending on the application of the end device, the mandatory regulations can differ from one to another.

For instance, IEC/EN 60335-1 is the basic requirement for Household appliances’ design, aiming to prevent foreseeable hazards ones could encounter when using the end device. Furthermore, IEC/EN 60335-2-29 defines the requirements in detail for battery chargers intended for household battery charging.

Specific charger applications such as AC EV Charger might require an additional power source to power the auxiliary and communication modules inside the such charger. For these kinds of applications, one has to evaluate on the system level if power supplies with more strict requirements are needed, such as the IEC/EN 61558-1 certification and compliance with OVC III (Overvoltage category III) protection level. Power Supplies with OVC III compliance can be integrated without adding an extra isolation transformer on the input side and gives your products the best out in terms of flexibility and costs in a minimized space. In addition, using such power supplies in AC Charters gives greater flexibility in terms of installation as these would allow the charger to be permanently connected to a distribution panel.

As for chargers intending to power up UPS systems and battery test systems, IEC/EN 62368-1 and IEC/EN 62477 are generally the safety regulations to comply with.

In addition, the standards related to electromagnetic compatibility (EMC) emission and immunity are equally important to take into consideration. In case the charging system is certified according to the IEC/EN 62368-1; the EN 55032 and CISPR 32 standards must be confirmed; in case the system needs to be certified for the IEC/EN 60335-1, the emissions and immunity according to the EN 55014 have to be met. Other major EMC regulations which must be complied with are the IEC/EN 61000-3 and IEC/EN 61000-4.

Therefore, clarifying the specific requirements for safety and EMC regulation standards will greatly facilitate the selection of the battery charger process.

Safety Regulation No. MEAN WELL Series
EN62368-1 HDR-15/30/60/100/150
ENC-120/180/240/360
NPB-120/240/360/450/750/1200/1700
RPB-1600 / RCB-1600 / DBR-3200/ DBU-3200
HEP-600C
CSP-3000
PHP-3500
RST-10000/ 5000
BIC-2200
TDR-240/480/960
WDR-60/120/240/480
Adapter Charger: GC30/120/160/220/330
OVC III (based on EN61558) HDR-15/30/60/100/150
*PHP-3500
OVC III (based on EN62368) IRM-30/45/60/90
EN60335-2-29 / EN60335-1 NPB-120/240/360/450/750/1200/1700
EN60335-1 IRM-60/*90
*PHP-3500

*=Regulation Designed Ready, NRE needed by users request

C. Installation

The working environment and condition are essential to the reliability and lifetime of both battery and charger; engineers must take into consideration the eventual working and storage condition of the battery charger to further choose an adequate model for the design.

For instance, chargers designed as 5G vibration-proof are more suitable for installation located in a mobile device. E.g., wheelchair, E-bike, mobile working station, camper van…etc. Whereas waterproof and dust-resistant IP67 chargers and power supplies are generally recommended for application under humid and dusty environment, both indoor and outdoor. 

On the other hand, it is not to forget that the working temperature is equally important to the longevity of battery charger and battery as the other working conditions mentioned earlier. Therefore, one should think about selecting a power source with adequate thermal dissipation design (e.g., convention cooling, forced air flow, conducted colling, water cooling…etc..) for the system too. 

Last but not least, the selection of battery charger is sometime limited by the available space or specific installation method too; a 19-inch rack cabinet will probably need an 1U Battery Charger (e.g., 1U-tall RCB-1600) to save space and a DIN Rail cabinet will most likely adapt a DIN RAIL power source (e.g., HDR series with OVC III  protection)…etc.  

Future postings and articles:

In the upcoming future, MEAN WELL will also share its knowledge regarding the booming Energy Storage System (ESS) field. For instance, how to use MEAN WELL Chargers (programmable 67~400VDC) in a High Voltage Direct Current (HVDC) application, as well as the know-how on digital communication protocols (e.g., PMbus and CANbus), which can further perform voltage and current control for the Energy sector. 

LEARN MORE ABOUT CHARGING POWER SUPPLIES

Explore our blog for insightful technical notes about Charging Applications.

Got questions?

Look at the section below to find the most frequently asked questions (with answers)
we received in Charging Applications.

The GTIN number can be found directly on the www.meanwell.com:

Tags: EAN, Gtin

Yes, MEAN WELL offers All-In-One Intelligent Security Power DRS-240/480 with built-in MODbus protocol as a standard option. The SHP-10K series has as optional model MODbus available. Please contact us if you require this.

Tag: MODbus

All the latest KNX firmware updates can be found on ETS Online Catalogue or MEAN WELL website dedicated to KNX products.

a. Got to KNX Building Automation Solution-MEAN WELL -> Downloads -> ETS Application Database

b. Click on Download button to see PDF file with all the hyperlink for specific products.

Tags: Firmware, KNX

A Surge Protection Device is optimized for a single voltage. Therefore, SPD should be chosen according to the actual operating voltage of the part that need to be protected.Secondly, the voltage protection level shows what is the maximum voltage appeared at output side when a specified surge is coming to the SPD. In general, the lower the voltage protection level, and the higher the discharge or surge current from SPD, means the better protection that the SPD provides.

Enclosed power supplies:

  • 35-125W applications: The RD, RT and RQ series provide dual, triple, and quadruple output.
  • 150-320W applications: The QP series comes with 4 different outputs.
  • 190-240W applications: The semi-potted HDP series provides dual output.

PCB-type power supplies:

  • 25-250W applications: The PD and PT series provide dual and triple output.
  • 45-200W medical applications: The MPD, MPT and MPQ series offer dual, triple, and quadruple output.

Configurable power supplies:

  • 400W fanless, the UMP-400 series is a convection cooled 1U height modular power supply and can provide up to 4 different outputs.
  • 450-1000W for ITE applications, MP series provides up to 7 different isolated outputs.
  • 650-1200W for ITE and medical applications, NMP series can provide up to 6 different isolated outputs with the NMS single output modules from 3~55VDC. With the NMD dual output module more outputs are possible in the 3~30VDC range. Additionally, the NMP offers a 5V AUX output.

Please also see our “NMP Page

Desktop-type power supplies:

  • 25-50W applications, our GP series is a triple-output type industrial adaptor. 

DC-DC modules:

  • 1-2W applications, the SMD-type DETN series comes with +/-5, 12 or 15V symmetrical outputs.
  • 3-30W applications, the DIP-type DCW, DCWN, RDDW, DKM, DKMW, DKA30 series come with +/- 5, 12 or 15V symmetrical outputs.
  • 20W ultra-wide input range requirements, the DIP-type RDDW20UW series can provide a +/-12, 15 and 24V symmetrical output.
  • 15W applications, the DIP-type DKE15 series offers a +/-5, 12, 15 or 24V symmetrical output.
  • 30W applications, the DIP-type TKA30 series offers a 5V output in addition to a +/-12 or 15V symmetrical output.
  • 10-15W applications, the on-board-type NSD series can provide a +/- 5, 12 or 15V symmetrical output.
Categories: Industrial, Medical, Others

The number of outputs, the available output voltage range and minimum load requirements are some key aspects to be considered when it comes to choosing a multiple output type PSU.

Basic power supplies in this category have a so-called minimum load requirement. These types of PSU rely on one same internal transformer to provide different outputs. For all outputs to work properly, a minimum current should always be drawn from the main output channel.

See below example how this is shown in the specification for the RPT-60A

More advanced power supplies such as the RT-65A do not have this restriction:

There are two options to select a multiple output PSU: a standard PSU with fixed output voltages, or modular power supplies. Modular PSUs can be personalized according to one’s systems requirements and offer much more flexibility than fixed output voltages PSUs. For instance, our NMP modular medical power supply series come with up to 6 slots for different output voltages from 3 to 55V which can be connected in series and parallel to adapt to each application.

Categories: Industrial, Medical, Others

This information can be found back in our installation manual, please visit “Installation Manual-MEAN WELL Switching Power Supply Manufacturer” and select the right product (group) and language.

Categories: Industrial, Others

Yes, CSP-3000 and PHP-3500-HV series both come with an inclusive choice of output voltages (120, 250, 400VDC). Also, our IP67 rated HEP-1000 series can provide DC output up to 100VDC.

Categories: Industrial, Others
Tag: DC Systems

All MEAN WELL power supplies come with at least one fuse on the line path1. The internal fuse is designed to handle the nominal current on the whole range of input voltages; for the same power, at low input voltages, the current drawn by the PSU will be higher:

LPV-100 input ratings (internal T 4AL-250VAC fuse)

If you want a more adapted protection for a specific input voltage, you could add an external fuse to protect the power supply. Considering that it will only protect the PSU (no other appliances connected after it), you should refer to the datasheet of the power supply and look for the typical input current under your input voltage. The fuse should be rated slightly higher than this current value. The selected external fuse should be a Slow-Blow type, this to avoid it is triggered by the inrush current of the power supply. For reference, most of MEAN WELL power supplies use type-T slow acting fuses. 

Further please take into consideration that fuses characteristics are given for an operating temperature of 25oC. Exceeding this value will lower the current rating and shorten its lifetime. Similarly, when operated in cold areas, the current rating will be increased.

Note 1: Except for DDRH-60 series

Categories: Industrial, Medical, Others

To download a digital version of our catalog, go to www.meanwell.com

1. Click on Products
2. Click on Downloads

Find our (3) LED driver, our (4) Industrial power and (5) short forms

Category: Others

MEAN WELL’s distributor information can be found on Distributor Network-MEAN WELL Switching Power Supply Manufacturer 

  1. Click on the region that you are located
  2. Select the country you are in
  3. Click on the search button
  4. Scroll down to see our local distribution channels
  5. Look for the distributor with a tick for the product group that you are looking for

MEAN WELL has the largest distribution network for serving your small and medium demand Power Supplies. You can find all MEAN WELL’s distribution channels on Distributor Network-MEAN WELL Switching Power Supply Manufacturer

OEM’s which have no sales channel for MEAN WELL products yet can contact us via the “Contact Us” form on this website.

MEAN WELL’s discontinued product schedule and End of Life products are normally updated 2 times per year, in January and in July and are published on www.meanwell.com. See FAQ “Where can I find MEAN WELL’s discontinued product schedule and End of Life information?

The normal procedure for E.O.L. is:

  1. The product or series is announced in the Discontinued product list in January or July and announced as NRND (Not Recommend for New Design) 
  2. 6 months later the lead time of the product or series will increase +30 days, the price will increase as well.
  3. Another 6 months later, the lead time will increase another +30 days (so + 60day compared to the original lead time), the price will increase again.
  4. Another 6 months later, the lead time will increase another +30day (so +90 days compared to the original lead time) and the price will increase again and additionally there will be a MOQ of 200pcs (and steps of 100 for higher quantities)
  5. After another 6 months the last buy is announced on the website. This will be the last opportunity to place an order for this product or series.

In total MEAN WELL’s End of Life, procedure will take 2 years. However, there are situations for instance that certification is expired, or some components can no longer be obtained by the market which will force to accelerate the EOL schedule. Therefore, it is always highly recommended from the moment that a product is on the discontinued list to design in one of our new generation products. If need any advice to this, please use the “Contact Us” function on this website.

MEAN WELL’s discontinued product schedule and End of Life products are normally updated 2 times per year, in January and in July. To see the full list, go to www.meanwell.com

1. Click on products

2. Click on Discontinued products for the schedule for the EOL schedule 

Click on EOL for the MEAN WELL products which are End Of Life

You can use the “Contact Us” function on this website

MEAN WELL’s website provides you all the basic information about our Power Supplies. This includes company news, product announcements, ISO certificates, Specifications, test report, Certificates, ROHS declarations, Reach declarations and many more.

MEAN WELL’s products can be found on www.meanwell.com

1. Click on products and select the product category

Or in case you already have a part number, you can use the search function on the website:

2. Use the search function on the website to find the right product

3. Fill in the series number in the search field (do not include the last extensions such as -12 in XLG-150-12)

4. Click the search button 

5. Click on the PDF icon to open the specification

Owing to line (voltage)-drop, we suggest the extension made from AC cable. In case DC cable extension is necessary, please consider Line-Drop leading to insufficient Vf so that the LED model or lamp may fail to switch ON. Moreover, EMC performance and characteristic may also be affected by DC cable extension.

Categories: LED Lighting, Others

First, you have to know your Led lamp specification in order to screen out a suitable Led driver range (Wattage, Voltage, Max Current CC or CV). From those ranges, further check a compatible dimming function. Hereunder is a table to show you the pros and cons of Dimming Function you can find in MW’s catalogue.

Categories: LED Lighting, Others

MEAN WELL has several charger products, and we suggest choosing them first. Chargers would be more suitable since they are designed for charging applications. Safety and approvals should be taken into account based on the final application. If you are unable to find a proper model in our charger series, our LED CC models can be used as charger. Please choose suitable products after confirming the current and voltage specification on the datasheet of the battery.

Categories: Charging, LED Lighting, Others

3 in 1 dimming circuit would drain 0.1mA per model. Dividing the rated current of the dimmer by the 0.1mA, and we could know how many units can be controlled by one dimming device. For resistance dimming applications, resistance for 100% dimming output would be 100K ohm divided number of models.

Categories: LED Lighting, Others

A LED strip is normally a Constant Voltage application (CV). For this type of CV application MEAN WELL has design the PWM, IDLV and ODLV series which will allow CV applications to dim.

Categories: LED Lighting, Others

3 in 1 dimming is the most common application used in LED dimming with the feature that it does not have to work with any specific dimmer. The only thing that has to be verified is that whether the dimmer (1~10V/10V PWM/resistance) is compatible with the definition advised in our specs.

Categories: LED Lighting, Others

All MEAN WELL chargers are preset for lead-acid batteries. For other products that can customize the charging curve (such as ENC / NPB series), customers can customize their charging curve depending on the charging and discharging characteristics of batteries. If you have other requirements, please use the contact us function on this website.

Categories: Charging, Others

Noise is directly related to the fan which is built into the power supply. Lowering the airflow of the fan means reducing the heat dissipation ability. It will also influence the reliability of the products. Furthermore, minimum airflow of fans is defined by Safety Organization and a safety appendage will be needed if using a new fan. If fan noise is a critical concern, we suggest to select FANLESS products or contact MEAN WELL for other possibilities according to the conditions of use.

Categories: Industrial, Medical, Others
Tags: fanless, Noise

There are two different applications when power supplies are connected in series. One is to generate plus minus voltage, another is to increase total output voltage. Connection methods are as follows:

(1) Connection for plus and minus voltage are shown as follow

(2) To increase the total output voltage (Output current remain the same). Diodes connect in parallel at output side of the driver is necessary to prevent damage during start up. The voltage rating of diode shall greater than V1 + V2(shown as figure below), in addition, peak forward surge current rating shall greater than rated current.

* Because part of the signal ground is shorted with output ground, strongly suggest to use isolated signals to achieve control scheme, in order to prevent damage to the product.

Categories: Industrial, Medical, Others

MEAN WELL has launched ENC, HEP-600C, GC, PA, PB, RPB and RCB series for battery charge applications (30~1000W). However, if these models cannot fulfill your requirements, there is an alternative solution. Power supplies with constant current limiting as overload protection are suggested. Charge current varies in battery percentage (full or flat), there is high possibility to trigger overload protection when battery is low, those with overload protection as hiccup or shutdown will stop charging the battery in low battery condition. Yet, using a power supply as charging purpose is considered as overload usage, modification is required. Please Contact Us for the request.

Categories: Charging, Industrial, Others

An adaptor may need connection of a power cord to receive energy needed from the utility. You can refer to the specification of the adaptor for the connector (AC inlet) at the adaptor end of the power cord; Different countries/regions vary in type of AC socket and voltage, please look at the table below for the information of the AC plug you need.

Categories: Industrial, Medical, Others

MEAN WELL’s LED product specification normally exhibits V-I characteristics. Per the characteristics, there are generally two types of drivers, the “CC” type and the “CC+CV” type. “CC” type of driver is suitable only for LED applications whereas “CC+CV” is for either LED applications or general switching power supply applications. The section that is not suitable for LED applications are represented by dotted line, and based on the protection procedures it can be categorized into hiccup mode and constant current mode; in this section, the tolerance of current is not defined but only the characteristic of current is displayed. If customers attempt not to see a very high current under short circuit conditions, those models with hiccup mode for this section can be selected; if there are applications with motors or capacitive load, those with constant current can be chosen.

Categories: LED Lighting, Others
Tag: CC+CV

There are 2 types of Power Factor Correction circuits; one is Single Stage; the other is Two Stage.

Single Stage power supply combines functions of power factor correction and converter in one circuit but Two Stage use two separate circuits. Compared to Single Stage, Two Stage design is more complex and costly, but the immunity performance of Two Stage power supply against AC mains is much better than that of Single Stage power supply. In addition, Two Stage power supplies manifest better ripple noises performance on output. Owing to that Single Stage is only suitable for fields with quality AC mains but Two Stage can be used in serious circumstances for LED drivers or as industrial switching power supplies.

Categories: LED Lighting, Others

It is the small unwanted residual periodic variation of the direct current (DC) output of a power supply which has been derived from an alternating current (AC) source. The wave form is shown as figure below.

There are two AC contents, also known as Ripple and Noise (R&N), on the DC output. The first one, coming from sine wave rectification, is at a low frequency which is 2 times of the input frequency; the second one is at high frequency which is from the switching frequency. For measuring high frequency noise, a configuration of an oscilloscope with a bandwidth of 20MHz, a scope probe with shortest ground wire possible, and add 0.1uF and 47uF capacitors in parallel with test point for filtering out noise interference are required.

Categories: Industrial, Medical, Others

1. To increase the reliability of the power supply, we suggest users choose a unit that has a rating of 30% more power than actual need. For example, if the system needs a 100W source, we suggest that users choose a power supply with 130W of output power or more. By doing this, you can effectively boost the reliability of the power supply in your system.

2. We also need to consider about ambient temperature of the power supply and whether there is additional device for dissipating the heat. If the power supply is working in a high temperature environment, we need to make some derating to the output power. The derating curve of “ambient temperature” versus “output power” can be found on our specifications.

3. Choosing functions based on your application:

  • Protection function: Over Voltage Protection (OVP), Over Temperature Protection (OVP), Overload Protection (OLP), and etc.
  • Application function: Signaling Function (Power Good, Power Fail), Remote Control, Remote Sensing, and etc.
  • Special function: Power Factor Correction (PFC), Uninterruptible Power Supply (UPS) function.

4. Make sure that the model qualifies for the safety standards and EMC regulations you need.

Categories: Industrial, Medical, Others

All MEAN WELL power supplies have an internal fuse except for the DDRH series.

Categories: Industrial, Medical, Others
Tag: Fuse

MEAN WELL’s Step files/ 3D files can be found on www.meanwell.com

  1. Use the search function on the website to find the right product
  2. Fill in the series number in the search field (do not include the last extensions such as -12 in XLG-150-12)
  3. Click the search button 
  4. Click on the PDF icon to open the specification
  1. Click on 3D OUTLINE
  2. Click on the model XLG-150-3D to download the step file.