Turbo M Series Onboard Charger

Transcript

 Turbo M Series onboard charger Operation Manual Model # Output Bank Max. Output Turbo M106 1 6 Amps Turbo M108 1 8 Amps Turbo M208 2 8 Amps Turbo M212 2 12 Amps Turbo M220 2 20 Amps Turbo M230 2 30 Amps Turbo M320 3 20 Amps Turbo M330 3 30 Amps Turbo M430 4 30 Amps Battery System (DC) 12V 24V 36V 48V Important Notice This manual contains important safety, operation, and installation instructions. Please read the entire instructions before using your Powermania Turbo M onboard battery charger. WARNING: CHECK BATTERY TYPE. This charger should be used to charge only Lead Acid type of 12V DC batteries; Flooded LeadAcid, AGM (Absorbent Glass Mat), and GEL (Gelled Electrolyte Lead-Acid). Use of this product to charge other types of batteries may cause batteries to burst and result in personal injuries. If you are unsure about the type of battery, please consult with battery manufacturers. WARNING: RISK OF EXPLOSIVE GASES! Working in the vicinity of lead acid batteries is dangerous. Batteries generate explosive gases during normal operation. For this reason it is extremely important to follow safety instructions each time before using this charger. WARNING: DO NOT USE 2-PIN AC ADAPTER/EXTENSION CORD. Do NOT use the charger with a 2-pin AC adapter or extension cord. Do NOT cut or make any modification to the factory equipped AC power cord. Doing so can result in serious personal injury. CAUTION: CONNECT ONLY TO PROPERLY GROUNDED OUTLET. The charger MUST ONLY be connected to a properly grounded AC outlet that is protected by Ground Fault Circuit Interrupter (GFCI) breaker. DANGER: ALWAYS UNPLUG AC POWER CORD BEFORE MAKING ANY DC WIRING CONNECTION. The AC power cord MUST be UNPLUGGED from the outlet BEFORE connecting any DC wire to batteries or making any DC wiring connection change. Fail to do so may cause electrical shock resulting in serious personal injury or death. 1 www.powermaniausa.com Contents Introduction...................................................................................................................3 Personal safety precautions.......................................................................................3 Precautions prior to charge battery..........................................................................3 Box contents.................................................................................................................4 Specifications...............................................................................................................5 Special features:...........................................................................................................8 Adaptive Loading.............................................................................................8 3-Stage Smart Charge.....................................................................................8 Battery Check Warning...................................................................................9 Battery Type Selector.................................................................................... 10 Connection Check Warning.......................................................................... 10 Safety features:........................................................................................................... 10 Ignition Protection......................................................................................... 10 Overheat Protection...................................................................................... 10 Over-Current Protection............................................................................... 11 Over-Voltage Protection................................................................................ 11 Reverse Polarity Protection.......................................................................... 11 Short Circuit Protection................................................................................ 11 Installing the charger................................................................................................. 12 Select battery type..................................................................................................... 13 Making DC connection.............................................................................................. 14 DC wiring connection charts:................................................................................... 15 1-bank charger (M106/M108)....................................................................... 15 2-bank charger (M208/M212/M220/M230)................................................. 16 3-bank charger (M320/M330).......................................................................20 4-bank charger (M430)..................................................................................29 Operating the charger................................................................................................46 Charge Status LED descriptions..............................................................................46 LED indicator descriptions........................................................................................ 47 Troubleshooting..........................................................................................................49 Maintaining the charger............................................................................................50 Warranty and service information............................................................................ 51 Contact information................................................................................................... 51 Memo............................................................................................................................52 www.powermaniausa.com 2 Introduction INTRODUCTION Thank you and congratulations on your new purchase of the Powermania Turbo M series onboard battery charger. This charger is waterproof, corrosion-resistant and shock-resistant—ideal for recharging and maintaining 12V DC batteries in marine applications and other harsh environments. Featuring Automatic 3-Stage Smart Charge and Battery Selector, this charger is designed to charge and maintain various types of 12V DC batteries using full automation. Our charging process has been proven to bring out the batteries’ full potential charge after each charging session while also extending their lifespan at the same time. The Turbo M also comes equipped with extensive safety features and intuitive LED indicators to help protect your investment, the charger itself, and its connected batteries and devices. Please visit our website www.powermaniausa.com for the latest product updates and information. PERSONAL SAFETY PRECAUTIONS 1. Someone should be within the voice range or close enough to come to your aid when working near a Lead-acid battery. Work in a well ventilated area away from ignition sources. 2. Have plenty of water and soap nearby in case battery acid comes in contact with skin, clothes, or eyes. 3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries. 4. If battery acid contacts skin or clothing, wash them immediately with water and soap. If acid enters eyes, immediately flood the eyes with running cold water for at least 10 minutes and get medical attention. Follow battery manufacturer’s recommendations if you come in contact with acid. 5. Never smoke or allow open flame near batteries. 6. Do not drop a metal tool onto a battery as that may spark or short-circuit a battery and it may cause an explosion or fire. 7. Remove all personal metal items such as rings, bracelets, necklaces, and watches when working near batteries. A battery can cause short circuit currents that are high enough to weld metals and cause serious burns. PRECAUTIONS PRIOR TO CHARGE BATTERY • • • • • 3 Do not charge outside of battery manufacturer’s recommended temperature conditions. Do not use this charger to charge dry cell batteries for home appliances. Do not operate the charger if any of the prewired cables or LED’s is damaged. Make sure all onboard connected electronic devices are turned off. If a battery needs to be removed from the vehicle or boat to be charged, always remove the www.powermaniausa.com Safety Precautions grounded negative terminal from the battery first. • Be sure to have enough open space around the battery for good ventilation during charge. Gas can be forcefully blown away using a piece of cardboard or other non-metallic material as a fan. • Wear full eye protection when cleaning battery terminals in case corrosive materials get in contact with eyes. • Add distilled water in each cell until battery acid reaches levels specified by battery manufacturer. Do not overfill. For batteries without cell caps, please follow the recharging instructions provided by battery manufacturers. • If necessary, use only industrial grade, UL approved extension cord connecting to the charger. When using extension cord, connect the charger end first before you plug the extension cord to a power outlet. When unplugging, unplug the end connecting to power outlet first, and then unplug the end connects to the charger. • Make sure the AC power outlet you are connecting the charger to is GFCI (Ground Fault Circuit Interrupt) protected. BOX CONTENTS • • • • • Turbo M series charger prewired with one AC power cord and DC output cable(s) Operation manual Registration card 4 x installation screws Replacement fuses: • • • • • • • • • 1 x 10 Amp (Turbo M106) 1 x 10 Amp (Turbo M108) 2 x 10 Amp (Turbo M208) 2 x 15 Amp (Turbo M212) 2 x 25 Amp (Turbo M220) 2 x 35 Amp (Turbo M230) 3 x 25 Amp (Turbo M320) 3 x 35 Amp (Turbo M330) 4 x 35 Amp (Turbo M430) www.powermaniausa.com 4 Specifications SPECIFICATIONS Max. Input Current (@120V AC) Maximum Output # Output Bank (Prewired) Output Voltage Configuration Weight Dimension (Inch) Recom. Battery Capacity* M106 M108 M208 M212 0.9 Amp 1.2 Amps 1.2 Amps 1.8 Amps 6 Amps 8 Amps 8 Amps 12 Amps 1 1 2 2 12V DC 12V DC 12/24V DC 12/24V DC 5.2 lb. 5.2 lb. 5.6 lb. 5.6 lb. 61/2 x 41/2 x 21/2 61/2 x 41/2 x 21/2 61/2 x 41/2 x 21/2 61/2 x 41/2 x 21/2 24-60 Ah 32-80 Ah 32-80 Ah 48-120 Ah * All connected batteries combined 5 www.powermaniausa.com Specifications SPECIFICATIONS M220 M230 M320 M330 M430 2.9 Amps 4.3 Amps 2.9 Amps 4.3 Amps 4.3 Amps 20 Amps 30 Amps 20 Amp 30 Amps 30 Amps 2 2 3 3 4 12/24V DC 12/24V DC 12/24/36V DC 12/24/36V DC 9.2 lb. 15.6 lb. 9.7 lb. 16.2 lb. 16.7 lb. 81/4 x 53 /4 x 23 /4 10 3 /4 x 7 x 23 /4 81/4 x 53 /4 x 23 /4 10 3 /4 x 7 x 23 /4 10 3 /4 x 7 x 23 /4 80-200 Ah 120-300 Ah 80-200 Ah 120-300 Ah 120-300 Ah www.powermaniausa.com 12/24/36 48V DC 6 Specifications SPECIFICATIONS (All models) Nominal input voltage: 100V~240V AC Nominal input frequency: 50~60Hz Nominal output voltage/bank: 12V DC Power factor: 0.99 Efficiency: 84% Battery type setting: 1. Flooded (Lead-Acid) / AGM 2. GEL 3. AGM+ Max. Bulk time: 15 hours Max. Absorption time: 4 hours Operational temperature: -4°F ~ 122°F Storage temperature: -40°F ~185°F Output cable length: 6 feet / 182 cm Power cord length: 6 feet / 182 cm LED indicators: 1. Power 2. Charge status 3. Over-voltage / Overheat Indicator 4. Connection / Battery Check 5. AGM+ Charge Mode 6. GEL (Gel Cell) Charge Mode 7. Flooded (Lead-Acid)/AGM Charge Mode Special features: Adaptive Loading 3-Stage Smart Charge Battery Check Warning Battery Type Selector Connection Check Warning Safety features: Ignition Protection Overheat Protection Over-Current Protection Over-Voltage Protection Reverse Polarity Protection Short Circuit Protection Compliances: FCC Part 15 Class B (pending) CE (pending) IP65 (Splash-proof) Constructed in accordance to Marine UL 1236 7 www.powermaniausa.com Special features SPECIAL FEATURE: Adaptive Loading (not applicable to M106/M108) USER Fully charges all connected batteries in the BENEFIT: shortest time. 10 A 2A 10 A 18 A The Adaptive Loading feature dynamically adjusts the charger’s output level on each output bank. More charging power is allocated to battery that is low in charge, and less charging power to battery that is closer to being fully charged. In Scenario 1 (left chart), the two batteries have similar charge levels. The Adaptive Loading feature allocates approximately equally 10 amps (50%) of its 20 amp output to each battery. In Scenario 2 (right chart), the first battery’s is close to be fully charged while the second battery is discharged. The Adaptive Loading feature allocates only 2 amps (10%) to the first battery and the other 18 amps (90%) to the discharged one. Note that in both scenarios the charger utilizes its full output capacity (20 amps). In contrast to the other chargers with fixed output-per-bank constraints, the Turbo M charges all connected batteries to their fullest charge in the shortest time. SPECIAL FEATURE: 3-Stage Smart Charge USER Maximizes battery potential and prolongs BENEFIT: battery life. Turbo M charges battery in three sequential stages: Bulk, Absorption, and Float. This mechanism is proven to bring battery to its fullest charge, and also to maintain battery’s full charge from self www.powermaniausa.com 8 Special features discharge. At the first stage (Bulk), the charger provides its maximum constant current to fast charge the battery. The battery’s voltage rises as it absorbs the charge. When the battery voltage reaches 14.5V (Flooded mode*), it is about 80% recharged. The charger then moves to the second stage. At the second stage (Absorption), the charger continues to charge the battery at 14.5V (Flooded mode). The charging current slowly decreases as the battery charges up to 100%. When the battery is fully charged**, the charger then moves to the third stage. At the third stage (Float), the charging voltage is reduced to 13.4V (Flooded mode). The charger can be left connected to the battery indefinitely to maintain the battery’s full charge. If the battery loses a significant amount of charge from usage, the charger will start a new recharge cycle. * Please refer to page 47 for voltage settings on each charge mode. ** Full charge is signified by two conditions: 1. The charger’s output current drops to a minimal level. 2. The 4-hour Absorption period expires. If either one of these conditions are met, the charger will then move into the third stage (Float). SPECIAL FEATURE: Battery Check Warning • USER BENEFIT: • Warns user to check/replace defective battery. Warns user to turn off electronic devices. If the charger stays in the Bulk stage for more than 15 hours, it will escape from the Bulk stage, skip the Absorption stage, and move directly to the Float stage. However, in this scenario, the Charge Status LED will not display green as in a normal charging sequence. Instead, the Battery Check Warning LED will display solid yellow to warn user to check battery. This situation could be a result of defective battery cells or continuous current drawn from onboard electronic devices. 9 www.powermaniausa.com Special / Safety features SPECIAL FEATURE: Battery Type Selector USER BENEFIT: Compatible with various types of 12V batteries (Flooded Lead-Acid, AGM, High Power AGM, and GEL). The Battery Selector feature allows users to select different types of 12V batteries to charge. The initial factory setting is at “Flooded Lead Acid/AGM” charge mode. The other two charging modes are “GEL” charge mode and “AGM+” charge mode. Select “AGM+” charge mode when charging high power AGM batteries. Please refer to Table 1 on page 47 for different charge voltage settings at each charge mode. DO NOT MIX TWO OR MORE BATTERY TYPES TO ONE WARNING: CHARGER. ALWAYS CONNECT THE SAME TYPE AND SAME-AGED BATTERIES TO ONE CHARGER. SPECIAL FEATURE: Connection Check Warning USER BENEFIT: • • Alerts user if battery is not being charged. Warns user to check for broken fuses and loose cable connections. This feature helps ensure every battery is being charged. If the connection between the charger and the battery is broken, the Connection Check Warning LED will display blinking yellow. This may be the result of a blown fuse in one of the output cables. If any one set of output cables is left unconnected or if the connection is loose, the Connection Check Warning will also be triggered. SAFETY FEATURE: Ignition Protection USER BENEFIT: Eliminates fire sparks and prevents fire. The charger is encapsulated to prevent any internal spark from igniting external surroundings. Internal sparks may be potentially generated by misuse or component failure. SAFETY FEATURE: Overheat Protection USER Protects charger from inadequate cooling BENEFIT: environment. www.powermaniausa.com 10 Safety features The charger automatically shuts itself off if the ambient temperature rises above a safety threshold. This feature helps prevent damage to the charger from overheating. The charger will automatically turn itself on again once the ambient temperature drops to a safe level. SAFETY FEATURE: Over-Current Protection USER Protects battery and charger from over-current BENEFIT: damage. The charger limits itself to its maximum current output capacity. If a defective battery or its connected devices try to draw greater-than-provided current from the charger, the charger will prevent its charging current from exceeding the maximum output. SAFETY FEATURE: Over-Voltage Protection USER Protects battery from incorrect DC wiring BENEFIT: connections. The charger limits itself to the maximum of 16V DC output. The charger will shut off automatically if the battery’s voltage is higher than 16V DC. This feature helps prevent damage to the battery due to unintended over-voltage supply from the charger. Over-voltage supply may be the result of incorrect DC wiring connections or defective battery. SAFETY FEATURE: Reverse Polarity Protection Protects charger and battery from incorrect DC USER BENEFIT: polarity wiring connections (positive to negative or vice versa). The charger is equipped with safety fuses on its output cables. If user incorrectly connects a positive output cable to a battery’s negative terminal or vice versa, the fuse will be blown, thus disconnecting the charger and the battery. When replacing blown fuses, please replace with spare fuses provided with the charger or use fuses of the same rating and size. SAFETY FEATURE: Short Circuit Protection USER Protects charger and battery from short BENEFIT: circuit damages. This feature protects charger from sudden burst of excessive high current caused when a positive output ring terminal contacts a negative one. 11 www.powermaniausa.com Installation INSTALLING THE CHARGER The Powermania Turbo M series charger is designed to be mounted onboard. The chart below shows the proper orientation of the mounting position. The LED lights line up horizontally at the top and the output cables at the bottom. • • • • • • • Select a well ventilated area where there are at least 8 inches of clear air space around the charger. Make sure the charger’s output cables can reach all batteries from the mounting position. Do not mount the charger on carpeted, upholstered, or varnished surfaces. Make sure the mounting surface can firmly hold the charger with the provided screws. Place charger on the tentative mounting area. Use a pencil to mark position of each mounting hole. Use 1/8” drill bit to drill on the marked position. Align the charger to the drilled holes, and then secure the charger with provided screws. www.powermaniausa.com 12 Installation SELECT BATTERY TYPE The Battery Selector’s tip point can be switched among three positions as follows. From left to right, the first position (factory default) is for charging Flooded Lead-Acid type and AGM type battery. The middle position is for charging GEL (Gel Cell) type battery, and the right position is for charging High Power AGM type battery. Please refer to Table 1 on page 47 for voltage settings in each charge mode. L. Acd AGM GEL AGM+ To switch to a different charge mode, please follow these steps: 1. Make sure the charger’s power cord is 2. Loosen the screws from the battery selector. 3. Pull the battery selector straight out from the charger. 4. Place the battery selector back to the charger with the desired position. 5. Secure the screws back to the battery unplugged from the power outlet. selector. CAUTION: RISK OF PERSONAL INJURY The screws used to secure the battery selector must be 10mm or shorter. If the screws are longer than 10mm, the charger could be damaged and could result in serious personal injury. 13 www.powermaniausa.com DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. MAKING DC CONNECTION The following pages (p.15 - p.45) demonstrate proper DC wiring configurations for Powermania Turbo M series chargers. When making DC connections, make sure each set of output cables (one positive and one negative) is connected to the same battery set of terminals. The red wires are positive (shown as grey color on the charts) and the black ones are negative. Never connect a black wire (negative) to a terminal that is connected with a red wire (positive). Always connect ALL of the charger’s output cables to battery terminal(s). NEVER LEAVE ANY SET OF OUTPUT CABLES UNCONNECTED. The charger will display blinking yellow on the Connection Check LED if any output cable is not connected to battery terminal. It is recommended to CONNECT THE CHARGER’S FIRST OUTPUT SET (OUTPUT 1) TO MAIN HOUSE BATTERY. The first output set is located next to the AC cord. Please refer to the following legend reference used on the connection charts: Fuse holder Positive output (Red wire) Negative output (Black wire) Jumper cable (not included) AC input power cord www.powermaniausa.com 14 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 1A: Connecting 1-bank charger (M106/M108) to one independent 12V Output 1 battery. 15 www.powermaniausa.com DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 2-bank charger (M208/M212/M220/M230) to one Output 2 independent 12V battery. Output 1 Connection 2A: www.powermaniausa.com 16 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 2B: Connecting 2-bank charger (M208/M212/M220/M230) to two 17 www.powermaniausa.com Output 2 Output 1 independent 12V batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 2-bank charger (M208/M212/M220/M230) to two www.powermaniausa.com Output 2 serial-connected 12V batteries (24V). Output 1 Connection 2C: 18 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 2D: Connecting 2-bank charger (M208/M212/M220/M230) to two 19 www.powermaniausa.com Output 2 Output 1 parallel-connected 12V batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 3-bank charger (M320/M330) to one independent 12V www.powermaniausa.com Output 3 Output 2 battery. Output 1 Connection 3A: 20 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 3B: Connecting 3-bank charger (M320/M330) to two independent 12V 21 www.powermaniausa.com Output 3 Output 2 Output 1 batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 3-bank charger (M320/M330) to two serial-connected www.powermaniausa.com Output 3 Output 2 12V batteries (24V). Output 1 Connection 3C: 22 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 3D: Connecting 3-bank charger (M320/M330) to two parallel-connected 23 www.powermaniausa.com Output 3 Output 2 Output 1 12V batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 3-bank charger (M320/M330) to three independent 12V batteries. t3 pu ut O Output 2 Output 1 Connection 3E: www.powermaniausa.com 24 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 3F: Connecting 3-bank charger (M320/M330) to one independent and two www.powermaniausa.com t3 pu ut O 2 25 Output Output 1 serial-connected 12V batteries (24V). DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 3-bank charger (M320/M330) to one independent and two parallel-connected 12V batteries. t3 pu ut O Output 2 Output 1 Connection 3G: www.powermaniausa.com 26 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 3H: Connecting 3-bank charger (M320/M330) to three serial-connected www.powermaniausa.com t3 pu ut O 2 27 Output Output 1 12V batteries (36V). DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 3-bank charger (M320/M330) to three parallel-connected 12V batteries. t3 pu ut O Output 2 Output 1 Connection 3I: www.powermaniausa.com 28 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. 29 www.powermaniausa.com Output 4 Output 3 Output 2 Connecting 4-bank charger (M430) to one independent 12V battery. Output 1 Connection 4A: DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. www.powermaniausa.com Output 4 Output 3 Output 2 Connecting 4-bank charger (M430) to two independent 12V batteries. Output 1 Connection 4B: 30 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4C: Connecting 4-bank charger (M430) to two serial-connected 12V 31 www.powermaniausa.com Output 4 Output 3 Output 2 Output 1 batteries (24V). DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to two parallel-connected 12V Output 4 Output 3 Output 1 batteries. Output 2 Connection 4D: www.powermaniausa.com 32 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4E: Connecting 4-bank charger (M430) to three independent 12V 33 www.powermaniausa.com Output 4 Output 3 Output 2 Output 1 batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to one independent and two www.powermaniausa.com Output 4 Output 3 Output 2 serial-connected 12V batteries (24V). Output 1 Connection 4F: 34 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4G: Connecting 4-bank charger (M430) to three serial-connected 12V 35 www.powermaniausa.com Output 4 Output 3 Output 2 Output 1 batteries (36V). DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to one independent and two www.powermaniausa.com Output 4 Output 3 Output 2 parallel-connected 12V batteries. Output 1 Connection 4H: 36 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4I: Connecting 4-bank charger (M430) to three parallel-connected 12V 37 www.powermaniausa.com Output 4 Output 3 Output 2 Output 1 batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to four independent 12V 3 1 2 put Out t4 tpu Ou put Out put batteries. Out Connection 4J: www.powermaniausa.com 38 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4K: Connecting 4-bank charger (M430) to two independent and two 1 2 put Out Out t4 tpu 3 www.powermaniausa.com Ou put 39 Out put serial-connected 12V batteries (24V). DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to one independent and three 3 1 2 put Out t4 tpu Ou put Out put serial-connected 12V batteries (36V). Out Connection 4L: www.powermaniausa.com 40 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4M: Connecting 4-bank charger (M430) to two serial-connected (24V) and 1 2 put Out Out t4 tpu 3 www.powermaniausa.com Ou put 41 Out put two parallel-connected 12V batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to four serial-connected 12V 3 1 2 put Out t4 tpu Ou put Out put batteries (48V). Out Connection 4N: www.powermaniausa.com 42 DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connection 4O: Connecting 4-bank charger (M430) to two independent and two 1 2 put Out Out t4 tpu 3 www.powermaniausa.com Ou put 43 Out put parallel-connected 12V batteries. DC wiring connections CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID SETTING OFF CONNECTION CHECK WARNING. Connecting 4-bank charger (M430) to one independent and three 3 1 2 put Out t4 tpu Ou put Out put parallel-connected 12V batteries. Out Connection 4P: www.powermaniausa.com 44 DC wiring connections CONNECT ALL DC OUTPUT CABLES TO BATTERY TERMINALS TO AVOID SETTING OFF CONNECTION WARNING Connection 4Q: Connecting 4-bank charger (M430) to four parallel-connected 12V 1 2 put Out Out t4 tpu 3 www.powermaniausa.com Ou put 45 Out put batteries. Operating instructions OPERATING THE CHARGER 1. Install the charger and make appropriate DC wiring connections. 2. Choose appropriate setting on the Battery Selector. 3. Plug in AC power cord to properly grounded outlet. 4. The Power indicator LED will display green, indicating the presence of AC power. 5. The charger will automatically start a new charge cycle. CHARGE STATUS LED DESCRIPTION Charge Status Description LED Display Battery is discharged. The charger is recharging battery in the first stage (Bulk). At this stage, the charger provides its maximum constant current. The battery absorbs the charge and its voltage rises to a specific level (Uo) set Solid Red by the charge mode.* Once Uo is reached, the charger will then move into the second stage (Absorption). If Uo cannot be reached after 15 hours of uninterrupted charge in the Bulk stage, the charger will time out and skip to the third stage (Float). In this case, the Battery Check Indicator LED will display solid yellow. (Please see Troubleshooting.) Battery is about 80% charged. The charger is recharging battery in the second stage (Absorption). At this stage, the charger continues to charge battery at the constant voltage (Uo). The charging current slowly decreases as the battery charges Blinking Red up to 100%. Full charge is signified by two conditions: 1. The charger’s output current drops to a minimal level. 2. The 4-hour Absorption period expires. If either one of these condition is met, the charger will then move into the third stage (Float). * Please refer to Table 1 on page 47 for voltage settings in each charge mode. www.powermaniausa.com 46 Operating instructions Charge Status Description LED Display Battery is fully charged. The charger is maintaining battery from selfdischarge in the third stage (Float). At this stage, the charging voltage is reduced to a lower level set by the charge mode. The charger can be left connected to the battery indefinitely Solid Green to maintain the battery’s full charge. Meanwhile, the charger can also provide its maximum output current for external DC loads, in which case the charger would function as a power supply. If the external DC loads cause the regulated voltage to drop below 12.5V DC, the charger will start a new charge cycle. Table 1. Battery Voltage Settings Charge Mode AGM L. Acd Flooded (Lead-Acid) / AGM Voltage Voltage (Absorption) (Float) 14.5V DC 13.4V DC GEL GEL 14.1V DC 13.8V DC AGM+ AGM+* 14.7V DC 13.6V DC * AGM+ Mode is designed for charging High Power AGM batteries LED INDICATOR DESCRIPTION Icon Indicator POWER 47 Description GREEN: Power On www.powermaniausa.com Operating instructions LED INDICATOR DESCRIPTION Icon Indicator Description SOLID RED: Bulk stage CHARGE STATUS: AGM+ GEL L. Acd BLINKING RED: Absorption stage GREEN: Float stage OVER-VOLTAGE / BLINKING YELLOW: Voltage exceeds range OVERHEAT INDICATOR SOLID YELLOW: Temperature exceeds range CONNECTION CHECK / BLINKING YELLOW: Check fuse / DC BATTERY CHECK connections INDICATOR SOLID YELLOW: Check battery AGM+ CHARGE MODE GREEN: Charging in AGM+ mode GEL CHARGE MODE GREEN: Charging in GEL mode FLOODED(LEAD-ACID) / GREEN: Charging in Flooded (Lead-Acid)/ AGM CHARGE MODE AGM Mode AGM www.powermaniausa.com 48 Troubleshooting DANGER: ALWAYS DISCONNECT AC POWER CORD PRIOR TO MAKING ANY DC WIRING CONNECTION CHANGE OR CHECKING FUSE. TROUBLESHOOTING Problem Power indicator GREEN LED is not on. Overheat indicator LED displays SOLID YELLOW Possible Cause No AC input. Short circuit at DC output. Solution Check AC input connection. Make sure AC power is present. Check and correct battery wiring connection (Refer to wiring connection charts). Replace broken fuse if necessary.* Remove any objects obstructing airflow Ambient temperature around the charger. Wait for the charger to exceeds safe range.** cool down. Charge will start when the ambient temperature drops to the safe range. Check and correct battery wiring connection. (Refer to wiring connection charts.) Wait at least 30 seconds before plugging in AC power Over-Voltage again. indicator LED Battery voltage If Over-Voltage LED continues to display displays BLINKING exceeds safe range. blinking yellow even with correct wiring YELLOW connections, unplug the charger’s AC power input and stop using the charger to avoid possible damage to the battery and/or connected electronic devices. Battery Check indicator LED displays SOLID YELLOW One or more defective battery cells. Battery is continuously Turn off all electronic devices that might be drawing charge. drawing charge from battery. (Charger remains in Battery system Bulk stage for more capacity exceeds than 15 hours.) charger’s range. 49 Run battery test and replace defective battery. Reconfigure battery system to reduce its total Ah (Amp Hour) rating within the charger’s recommended Ah capacity. www.powermaniausa.com Troubleshooting DANGER: Problem Connection Check indicator LED ALWAYS DISCONNECT AC POWER CORD PRIOR TO MAKING ANY DC WIRING CONNECTION CHANGES OR CHECKING FUSES. Possible Cause Solution One or more outputs Make sure all charger outputs are properly are not connected to a connected to battery terminals. (Refer to battery terminal. wiring connection charts.) Fuse failure. Check for blown fuses on output cables and replace damaged fuses.* displays BLINKING Faulty terminal Clean battery terminals and tighten all wiring YELLOW connections. connections. Reverse polarity on DC wiring connections. Correct connections with matching polarity. Check fuses on output cables and replace any damaged fuses.* * When replacing blown fuses, please replace with spare fuses provided with the charger or use fuses of the same rating and size. Please contact Powermania for more information on the replacement fuses. ** The operational ambient temperate range is -4°F~122°F (-20°C~50°C). When the ambient temperature rises outside the range during operation, the charger’s Overheat LED will display solid yellow and the charger will be shut off automatically. Once the ambient temperature cools down to a safe range, the charger will be turned on again automatically. MAINTAINING THE CHARGER The Powermania Turbo M charger requires no specific maintenance. However, it is recommended to do the following to ensure reliable and optimal performance from your battery: • Regularly clean battery terminals and charger’s output ring terminals with baking soda and tighten all DC wiring connections. • Regularly check and maintain proper battery electrolyte level following battery manufacturer’s instructions. It is recommended that you keep the charger’s power on to maintain the connected batteries during long storage periods. This method has been proven to extend battery life. www.powermaniausa.com 50 Other information WARRANTY AND SERVICE INFORMATION Powermania, at its discretion, provides 2-year limited warranty on Turbo M chargers against defects in material or workmanship under normal use. The warranty coverage period is calculated as follows: • • If customer provides a valid purchase receipt, the 2-year period is calculated from the date of purchase. If customer cannot provide a valid purchase receipt, the 2-year period is calculated from the manufacture date based on serial number. The following conditions are NOT covered under warranty: • Physical damage • Normal wear and tear • Damage caused by accidents, misuse, or alteration of the product. Do NOT contact the distributor or dealer from whom you purchased the charger for service or warranty support. Please contact Powermania directly for service or warranty inquiry. Customer is responsible for paying the cost of shipping the defective product to Powermania. CONTACT INFORMATION Powermania, Inc. 3333 Bowers Avenue, Suite 130 Santa Clara, CA 95054 Tel: (888) 581-8168 Fax: (408) 986-8306 email: [email protected] www.powermaniausa.com 51 www.powermaniausa.com Memo www.powermaniausa.com 52 Memo 53 www.powermaniausa.com Memo www.powermaniausa.com 54  RW1106 Rev B