Hulk HU6525, User Manual

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Declaration of Compliance
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21
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1. HULK Professional HU6525 / HU6540 DC-DC Chargers is designed for charging one 100-1000Ah 12V Standard
Automotive Lead-Acid, GEL, AGM, Calcium, SLI, Deep Cycle type or one 25-1000Ah Lithium rechargeable battery.
The charger is not intended to supply power to a low voltage electrical system other than to charge a battery.
Do not use it for any other purpose.
2. DO NOT ATTEMPT TO CHARGE A NON-RECHARGEABLE BATTERY (PRIMARY CELLS). They may burst
and cause injury to people and damage to property.
3. Never charge a frozen battery. Never charge a damaged battery.
4. Explosion hazard! A battery being charged could emit explosive gasses. Avoid smoking or open sparks or flames
near the battery. Explosive and flammable substances such as fuel or solvents should not be kept near the
charger or the battery.
5. Danger of chemical burns! Battery acid is highly corrosive. If your skin or eyes are exposed to acid, immediately
rinse the affected part of the body with excessive water and seek medical advice.
6. DO NOT alter or disassemble the Battery Charger under any circumstances, incorrect reassembly may result in
electric shock or fire. Unauthorized disassembly, repairs or modifications will void the official warranty.
7. Never place the charger above the battery being charged, gases from battery will corrode and damage the charger.
8. During charging, batteries must be placed in a well ventilated area.
9. Children or people with reduced physical, sensory or mental capabilities or lack of experience and knowledge
should not use this appliance.
Congratulations on your purchase of the HULK Professional HU6525 / HU6540 DC-DC Charger 7-Step
fully automatic switch-mode battery charger, designed for charging a variety of lead-acid rechargeable & Lithium
auxiliary batteries by providing a proprietary algorithm to each specific battery type.
HU6525 / HU6540 chargers include all the features needed to achieve and maintain the auxiliary battery
to its optimum condition at all times. HU6525 / HU6540 chargers also feature MPPT (Maximum Power Point
Tracking) solar regulator technology, allowing you to deliver maximum amount of power from the solar panels
to the auxiliary battery.
Safety Information
1m
2m
3m
4m
5m 4 mm
2
7 mm
2
10 mm
2
13 mm
2
16 mm
2
5 mm
2
10 mm
2
15 mm
2
20 mm
2
25 mm
2
Note:
Please tighten the screws properly and
ensure that none of the screws are
loose. Max torque is 3N.m for the M5
screws and 8N.m for the nuts.
A. Connect one end of the common ground cable to the “GND” terminal of the charger.
B. Connect the grounds of solar panel, vehicle starter battery, DC input ( for HU6540 only ) and Auxiliary battery
to the other end of the common ground cable.
C. Connect one end of the auxiliary battery output cable to the “AUX” terminal.
D. Connect the other end of the auxiliary battery output cable to the positive post of the auxiliary battery.
Insert an inline midifuse holder (P/N FU6061) and 60A fuse near the Auxiliary battery.
E. At this point, “OK/ERROR” LED should turn GREEN if the auxiliary battery voltage is within the charging
range and default “AGM/GEL” battery is selected.
F. Connect one end of the alternator input cable to the “ALT” terminal of the charger.
G. Connect the other end of the alternator input cable to the positive post of the Main battery. Insert an inline
60A fuse near the Main battery.
H. At this point, “ALT” LED should turn-on if the alternator voltage is within the acceptable range.
I. Connect one end of the solar input cable (if available) to the “SOLAR” terminal of the charger.
J. Connect the other end of the solar input cable to the positive output of the solar panel.
K. At this point, “SOLAR” LED should turn-on if the solar voltage is within the acceptable range.
L. Connect one end of the DC input cable (if available) to the “DC” terminal of the charger ( for HU6540 only ).
M. Connect the other end of the DC input cable to the positive output of the DC supply. Insert an inline 60A
fuse for additional protection from short circuit i.e. cables touching the chassis ( for HU6540 only ).
N. At this point, “DC” LED should turn-on if the DC voltage is within the acceptable range.
O. “CHARGE” LED will begin blinking to indicate if charging is in progress.
Index
Electrical Specifications
Selecting Battery Type
Automatic Input Selection
Removing the Cover
Parts of the Charger
•
No external relays needed.
•
By default, when there are multiple inputs
available, the charger chooses which input
should be active according to priority.
1. Alternator linked to starter battery
2. Unregulated solar power using built-in
Maximum Power Point Tracking (MPPT)
Solar Controller
3. DC Supply (HU6540 only)
•
HU6540 has one more input terminal for DC
voltage source i.e. ACDC power supply,
wind turbines, etc. The charger tracks and
utilizes the power capacity of the source.
In order to access the charger terminal, select the battery type and to
install the temperature compensation & ignition over-ride cables, the
top cover needs to be removed.
Loosen the two screws as indicated to release the cover.
1 Top Cover
2 Status Membrane
3 Remote Monitor Port
4 Metal housing
5 Mounting Feet
6 Solar Terminal
7 Alternator Terminal
8 Common Ground Terminal
9 Ignition Override Terminal
10 Temperature Sensor Terminal
11 Auxiliary Battery Terminal
12 Terminal Block
Product Package Contents
HU6525 or HU6540 Battery Charger
Battery Temperature Sensor 3.5m cable
Ignition Sensor M3 Ring Terminal
Remote Display
HU6526 (optional)
User’s Manual
HU6525 or HU6540 Terminal Block (optional)
Ferrite Clamp (for HU6540 only)
Mounting Screws
Wire Size Recommendation
Use the recommended minimum cable cross
section area (mm2) to avoid significant voltage
drop (approx. 0.35V). Note: Radiated Emission
was tested using 1m cable.
Mounting the Charger
Connecting the Charger
1. The charger can operate in harsh environments but
it is best to locate far away from heat sources and
excessive vibrations; and close to the auxiliary
battery. It can be installed in any position, vertically
or horizontally.
2. Use the four mounting feet of the charger to attach
to a secure flat surface.
3. Drill the four fixing holes and use the screws
included in the package to fasten the unit.
4. Remove the top cover before wiring the charger.
Put the top cover back after wiring for protection
of the terminals.
Item
AGM/Gel
Wet
Ca+
Li-ion
OK/Error
OK/Error
Alternator
Solar
DC (DX-40)
Charge
Charge
Float
Float
LED
ON: Blue
ON: Blue
ON: Blue
ON: Blue
ON: Green
ON: Red
ON: Yellow
ON: Yellow
ON: Yellow
Blinking: Blue
ON: Blue
Blinking: Blue
ON: Blue
Indication
Battery Type Selection (default)
Battery Type Selection
Battery Type Selection
Battery Type Selection
Battery OK.
Battery Bad/Charging Error/Fault
Active Input Indication
Active Input Indication
Active Input Indication
Bulk Charging Stage
Absorption Charging Stage
Battery Analysis
Float Stage
Note:
Please tighten the screws
properly and ensure that none
of the screws are loose. Max
torque is 3 N.m for the M5
screws and 8 N.m for the nuts.