Safety Instructions
General Precautions
Precautions against Gas Explosions
Precautions when Handling Batteries
Do not use on the
positive battery terminal for this connection!
Product Characteristics
Easy installation: It could not be easier. For the basic system only 4 connections are
Before connecting and running your Sterling alternator-to-battery
required: one from the alternator(s), one to each battery bank and one to the common
charger, read the complete instructions and all cautionary labels
negative. Apart from the additional negative connection most of these cables will be
on the unit and on the batteries. Only a correct installation
on board anyway.
according to these instructions will let you take full advantage of
your alternator-to-battery charger.
Advanced charging technology: Intelligent, software-controlled, 4step charging of
the domestic battery including temperature compensation.
Always install the unit in a dry, cool and well-ventilated
No interference with engine electronics: Because the system does not increase the
place. Any contact with water and heavy humidity has to be avoided. Do not
voltage of the starter battery there is no risk of problems with the electronic engine
cover the fans to prevent the unit from overheating. Make sure all cables
management system.
have the appropriate size and are in good condition. Do not run the unit with
cables that are damaged or otherwise inappropriate.
No work on the alternator required: Absolutely no changes to the alternator are
required. As a result no warranty conflicts can arise.
The alternator-to-battery charger contains
Suitable for multiple alternators: Unlike other systems the alternator-to-battery
electrical components which may produce sparks in event of failure. In order
charger can be used simultaneously on more than one alternator, saving even more
to avoid the risk of fire or explosion, do not install the unit in rooms
installation work and money.
containing batteries or highly inflammable materials or in any place requiring
explosion-proof equipment. This includes any room with petrol, gas or diesel
Starter battery priority: The system ensures that the starter battery is always kept in
driven engines or with tanks or piping used for any such substance. Before
operational condition.
starting to install the charger please ensure that there is sufficient ventilation.
Intelligent fault protection: The unit comprises multiple safety features and fault
In order to prevent the formation of explosive gases make sure that the
indicators. Even in the unlikely event of a complete failure, the unit will still work as
batteries have not been charged for at least 4 hours prior to installation.
a split charge diode.
Someone should be within earshot, i.e.
Enhanced installation options: The unit comes with temperature sensors for the
close enough to come to your aid when working near a lead-acid battery.
battery and the alternator. It can be enhanced by an optional remote control.
Have plenty of water and soap nearby in case battery acid comes in contact
with skin, clothes or eyes. Wear complete eye protection and protective
clothing. Avoid touching the eyes while working with a battery.
Basic Installation
If battery acid contacts skin or clothing, wash immediately with soap and
water. If acid enters the eye(s), flood eye(s) with running cold water for at
least 10 minutes and seek medical attention immediately.
Never smoke or allow a spark or flame in the vicinity of a battery or the
engine.
Install the unit in a cool and well-ventilated position close to the alternator(s). Also,
Work with extra caution to reduce the risk of dropping a metal tool onto a
the installation point has to be dry and free from heavy condensation since the unit is
battery. It may create sparks or short-circuit the battery or other electrical
not waterproof. Do not fit it in a closed box as this might lead to overheating of the
parts that may cause an explosion.
unit and reduced performance.
Remove all personal metal items such as rings, bracelets, necklaces, watches
The unit has three temperature-controlled fans. Therefore they will run more often
and jewlery when working near a battery. A battery can produce a short-circuit
when the unit is installed in a place with a high ambient temperature.
current high enough to weld a ring or any other metal which will lead to
Before connecting the unit to your alternator(s) make sure that your alternator-to-
serious burns.
battery charger is rated for the maximum ( combined ) output of the alternator(s).
Never charge a frozen battery.
Connect the main alternator/ s output(s) (B+) to the center stud marked
“ALTERNATOR INPUT. Then simply connect the other studs to the engine battery
General Overview
and to the domestic battery, respectively. Make sure that the cables used can carry
T
he Sterling alternator-to-battery charger is a fully automatic, electronic
the full current of the alternator(s). Choose a cable size that can carry at least twice
multi-stage split-charge system which charges two banks of batteries from one
as much current than required. For example, if you have a 70A alternator, then use a
or more alternators. It combines an advanced split charge diode system with a
140A cable to reduce voltage drop in the cable and improve performance
powerful voltage amplifier. The unit has one input to connect to one or more
If you are only going to charge one bank of batteries, then use the “DOMESTIC
alternators and two outputs to charge two different battery banks.
BATTERY” output only. The “START BATTERY” output can remain unused
The output marked “starter battery” is a straight channel through a diode; this
without affecting the performance of the unit.You can split the boosted domestic
is the channel that is connected to the boat / vehicle engine system. In order to
battery side by using a Sterling Pro Split R 0 volt spliting system or the Current
avoid any conflicts with an electronic engine management system, there is no
limiting VSR.
boost function on this channel.
The unit has a short negative wire which has to be extended and connected directly
The output marked “domestic battery” comprises an intelligent, software-
to the alternator negative (or case) or the common battery neg using a 60A cable.
controlled boost function which charges the domestic battery bank up to five
If you currently have a split charge diode, then the three positive wires are already
times faster and much more efficient than a standard alternator could do. In
there. Simply replace the split charge diode with the alternator-to-battery charger and
addition, the batteries will take in up to 50% more charge current, allowing
connect the negative wire to the alternator neg or the nearest main comm neg.
you to utilize their full capacity.
Important: If your alternator has got its own battery voltage sense wire, then this has
While the alternator-to-battery charger greatly improves the charging of the
to be removed from the battery terminal and should be connected to the alternator’s
domestic battery bank, the starter battery has always priority, ensuring that the
own B+ output instead. This will prevent contradictory regulation between the
engine can be started at any time. Under no circumstances will the system
alternator and the alternator-to-battery charger.
allow the starter battery to drop below 13V.
Extended Installation
Additional functions protect your electrical system and your batteries from
For additional functions and improved performance some extra features can be
possible faults such as overcharging or over temperature caused by the
installed. Note that this extended installation is optional and is not required for the
alternator to battery charger. Any fault on the system will be indicated by a
unit to work.
number of LEDs or on the optional remote control unit.
Battery Temperature
: Using its ring terminal end, connect one of the enclosed
temperature sensors to your domestic battery’s negative post.
In order to maximist the alternator output current, the alternator-to-battery
Connect the two small wires on the
charger pulls the alternator output voltage down to about 13,3V. Then this low
other end to the small terminals marked “battery temp”. Be careful not to damage or
voltage is amplified to a higher voltage suitable for effective battery charging,
alter the temperature sensor in any way! The system will then sense the battery
i.e. 14.1V to 14.8V. The unit’s intelligent software automatically calculates the
temperature and change the output voltage in accordance with the recommended
optimum charge cycle and absorption time. When the batteries have been
temperature compensation for the selected battery type.
fully charged, the voltage is reduced to float voltage (appr. 13.5V to 13.8V) if
possible, depending on the output voltage of the alternator.
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
How it works
The temp sensor does not
need to be used for the unit to work,
Important: These guidelines refer to the connections
that have to be made for the correct installation of the Sterling Alternator-to-Battery
Charger. On an existing system you may also be required to remove some of the
original connections that were used to charge the batteries prior to the installation of
the unit.
A
LTERNATOR
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TO
-B
ATTERY
C
HARGER
I
NSTRUCTIONS
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