Download Turbo M Series onboard charger


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.
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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
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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
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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)
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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
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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
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12/24/36
48V DC
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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
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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
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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:
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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
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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
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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
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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
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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
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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
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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
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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
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O
Output
2
Output
1
Connection 3E:
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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
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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
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O
Output
2
Output
1
Connection 3G:
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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
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t3
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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:
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DC wiring connections
CONNECT EVERY DC OUTPUT CABLE TO BATTERY TERMINAL TO AVOID
SETTING OFF CONNECTION CHECK WARNING.
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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.
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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
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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:
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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
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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
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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
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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
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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
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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:
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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
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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:
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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
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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:
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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
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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:
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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
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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.
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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
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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
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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.
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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.
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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]
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
RW1106 Rev B