Hulk HU6525, User Manual

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Declaration of Compliance
20
21
19
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.
+
-
Connecting the Charger using the Terminal Block
A,
B,
C,
D,
E,
F,
G,
H,
I,
J,
K,
L,
M,
N,
O,
P,
Q,
R,
Connect the matching terminal block to the charger and properly fasten the screws attaching the terminal
block to the charger.
Flip the terminal block cover to access the ports for the cables.
Connect all the ground cables to any of the “GND” ports of the terminal block.
Connect the other end of the ground cables to each of the grounds of main battery, solar panel, DC input
( for HU6540 only ), and auxiliary battery.
Connect one end of the auxiliary battery output cable to the “AUX” port of the terminal block.
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.
At this point, “OK/ERROR” LED should turn to GREEN if the auxiliary battery voltage is within the charging
range and default “AGM/GEL” battery is selected.
Connect one end of the alternator input cable to the “ALT” port of the terminal block.
Connect the other end of the alternator input cable to the positive post of the main battery. Insert an inline
midifuse holder (P/N FU6061) and 60A fuse near the main battery.
At this point, “ALT” LED should turn-on if the alternator voltage is within the acceptable range.
Connect one end of the solar input cable (if available) to the “SOLAR” port of the terminal block.
Connect the other end of the solar input cable to the positive output of the solar panel.
At this point, “SOLAR” LED should turn-on if the solar voltage is within the acceptable range.
Connect one end of the DC input cable (if available) to the “DC” port of the terminal block ( for HU6540 only ).
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 ).
At this point, “DC” LED should turn-on if the DC voltage is within the acceptable range.
“CHARGE” LED will begin blinking to indicate if charging is in progress.
Close and latch the terminal block cover to protect the ports.
Temperature Sensor and Ignition Sensor Connection
Ignition
Temperature sensor
Temperature Sensor Installation
Ignition Sensor Installation
Ignition sensor is another optional feature used to detect vehicle ignition
and identify that the vehicle is running. This ignition connection enables a
“low input operation” mode for compatibility with smart (variable voltage)
alternators found in modern vehicles.
HU6525 / HU6540 supports vehicles operating with
24V alternators. These vehicles usually have two
12V main batteries connected in series. The output
of HU6525 / HU6540 will charge 12V auxiliary
battery or battery bank.
An AC powered battery charger can be connected
to the auxiliary battery without disconnecting the
HU6525 / HU6540 if it is in standby mode and not
in any charging cycle.
The HULK HU6526 Monochrome LCD display
monitors the charging status of HU6525 / HU6540 .
The unit monitors voltage, current, state of charge
and any warnings related to the charging.
Temperature sensor is an optional feature used to compensate for the
auxiliary battery temperature and protect the battery from overheating.
1. Cut a desired length of cable (recommended AWG22) and crimp to
the M3 ring terminal included with the package to make the Ignition
Sensor cable.
2. Connect the ring terminal end of the Ignition cable to the “IGN” terminal
of the charger.
3. Connect the sensor end of the Ignition cable to the ignition wiring of
the vehicle.
1. Connect the ground of the Temp Sensor cable to the “GND” terminal
of the charger.
2. Connect positive of the Temp Sensor cable to the “Sensor” terminal
of the charger.
3. Connect the sensor end of the Temp Sensor cable to the negative pole
of the Auxiliary battery.
1 - Power: Single press toggles the display to
standby mode or active mode.
2 - Mode: Single press toggles the display
mode from three choices.
3 - Brightness Up: There are five levels of
backlight brightness. Default is maximum level.
Each single press will increase the brightness
by one level up to the maximum level.
4 - Brightness Down: There are five levels of
backlight brightness. Default is maximum level.
Each single press will reduce the brightness
by one level down to minimum level.
a) Active Input Source: The charger automatically chooses which
input to use depending on the current condition. Shows STBY
if not charging.
b) Input Voltage: Actual voltage level of the active input source.
c) Output Current: Actual current level that is being charged to
the auxiliary battery.
d) Output Voltage: Actual voltage level of the auxiliary battery.
e) Battery Temperature: The temperature of auxiliary battery.
f) Battery Type: The type of auxiliary battery selected
(AGM/Gel, Wet, Calcium, Li-ion).
g) Percentage of Charge: Actual level of charge of the main
and auxiliary battery shown as graphs.
1. Choose an appropriate location for mounting the monitor.
It should be visible enough to see while driving.
2. Fix the wall mount using screws or double-sided adhesive tape.
Wall mount fixture enables adjusting the monitor for better
viewing angle.
3. Attach the monitor housing to the wall mount fixture by fitting
the ball joint stick to the slot at the back of the monitor and
sliding it to lock.
4. Connect the USB Type-C end of the monitor cable to the
HU6526 USB connector slot. Gently push the cable plug into
the display mating connector until it clicks into position.
5. Connect the other end of the monitor cable to the HU6525 / HU6540
6-pin connector slot. Follow the marking on the cable plug and
mating connector for correct orientation. Gently push the cable
plug into the display mating connector until it clicks into position.
6. At this point, display icons should be visible in the screen if the
charger is powered.
7. Press the Power button to toggle the monitor from standby
mode and operating mode.
8. To disconnect Data Cable from the charger, apply little pressure
on the sides of the Data Cable plug and slowly pull it back.
HU6526 Remote Display
Remote Display Interface
Trouble Shooting
Remote Display Warning Messages
Remote Display Installation
a) – Low Voltage Warning or Battery not connected. The main or Auxiliary battery voltage is lower than 11.4V
or there is no connection to one of the batteries. Fuses and connections must be checked.
b) Flashing Voltage with – Battery won't hold charge.
c) OVP – Over Voltage Protection. High voltage is detected at any of the SOLAR, ALT, AUX or DC terminals.
d) OCP – Over Current Protection. The detected charge current is higher than specifications. Check short
circuits or cable faults and then reset the whole system.
e) OTP – Over Temperature Protection. Charging is suspended to prevent damage to the battery when the
detected battery temperature is above 50ºC. Charger also stops if internal temperature is above 115ºC.
The device will resume charging once temperature drops to a safe level.
f) REV – Reverse Polarity Protection. The auxiliary battery connection is reversed. Check the connection.
g) BAD – Battery can’t be recovered. The charger has detected that the auxiliary battery is unable to be charged
safely. Inspect the battery, replace if necessary.
HU6540
Li-ion Wet OK /
Float DC Ca
+
AGM/Gel
Battery
Charge
HU6525
Li-ion Wet OK /
Float Ca
+
AGM/Gel
Battery
Charge
Keep this manual in a safe place for future reference.
For Your Safety
HU6526 Dimensions
Additional Applications
Do not operate the battery charger unless you have read and understood this manual and installed the charger
as per instructions.
Safety Information ..................................................................................................................... 3
Product Package Contents ....................................................................................................... 4
Wire Size Recommendation ..................................................................................................... 4
LED Indications ......................................................................................................................... 5
Automatic Input Selection ........................................................................................................ 6
Removing the Cover ................................................................................................................. 7
Parts of the Charger .................................................................................................................. 7
Mounting the Charger ............................................................................................................... 8
Connecting the Charger ............................................................................................................ 9
Connecting the Charger using the Terminal Block ............................................................... 11
Temperature Sensor and Ignition Sensor Connection ......................................................... 13
Ignition Sensor Installation.................................................................................................. 14
Temperature Sensor Installation.......................................................................................... 14
HU6526 Remote Display ............................................................................................................ 15
Remote Display Installation.................................................................................................. 16
Remote Display Interface..................................................................................................... 17
Remote Display Warning Messages.................................................................................... 18
Trouble Shooting ...................................................................................................................... 19
Electrical Specifications .......................................................................................................... 21
Charging Algorithm ................................................................................................................. 22
Applications ............................................................................................................................. 23
Dimensions .............................................................................................................................. 25
25A 40A
22
24 23
25 26
6
AC
Battery
Charger
24V 12V
24V vehicles
Trailer or Caravan Installation
External battery charger connection
Important information is displayed in real time. Warning
messages also appear if there is an abnormal condition.
Output
Voltage
Current
Power
Operating Temp
Protection Class
Standard
Dimension (mm)
Weight (g) 800 1140
Remote Display Optional
Battery Type Bulk Voltage Float Voltage
AGM / Gel
Standard Wet
Calcium
Lithium-Ion
max. max.
max. max.
DC Input
Low Voltage Turn OFF
Low Voltage Turn ON
Over Voltage Turn ON
Over Voltage Turn OFF
For safety reasons, the battery type can only be selected when the auxiliary battery is not connected,
“OK/ERROR” LED is RED.
Press the “Battery” button to select the correct auxiliary battery type to be charged (AGM/Gel,
Standard Wet, Calcium, and Lithium-Ion).
Replacing the Battery
Remove the connections of all the input sources before disconnecting the battery.
Input Range
Alternator
Solar
DC
Solar MPPT
12V Panel
18V Panel
24V Panel
12V Alternator Input
Low Voltage Turn OFF
Low Voltage Turn ON
Over Voltage Turn ON
Over Voltage Turn OFF
24V Alternator Input
Low Voltage Turn OFF
Low Voltage Turn ON
Over Voltage Turn ON
Over Voltage Turn OFF
Ignition Override
Low Voltage Turn OFF
Low Voltage Turn ON
Over Voltage Turn ON
Over Voltage Turn OFF
max. max.
max. max.
max. max.
Using the Ferrite Ring (HU6540 only)
For optimum EMI
results, put the
pair of input
cables through
the ferrite as per
below diagram.
Standard Applications
Multiple Auxiliary Batteries
HU6540 Dimensions HU6525 Dimensions
178mm
59mm
128mm
138mm
160mm
123mm
126mm
149mm
110mm
158mm
53mm
15 16
17 18
13 14
11 12
1 2
4
3
6
5
8 7
9 10
Connector to
MAIN battery
+ -
Remote Monitor HU6526 Wall Mount Bracket Cable
19 19
82
70
46
60
40
The HU6525 / HU6540 can be installed in a Trailer or
Caravan that houses the auxiliary batteries. In this
connection, the HU6525 / HU6540 can work as a stand
alone solar charger and also has a removable
connection to the charging system of the towing
vehicle. More than one solar panel of the same
kind can be connected in parallel provided the
maximum voltage is below 42V.
The HU6525 / HU6540 can charge multiple auxiliary
batteries connected in parallel. This is common in
trailers or caravans with large 12V battery banks.
Ensure that the parallel batteries are matched in
type, capacity and age.
50º
LED Indications
Reverse Polarity
Over Voltage
Over Current
Device Protection
Over Temperature
Bad Battery Detect
High temperature.............
Low Temperature........... -17mV per°C above 30°C
+17mV per °C below 21°C
50°C
Battery Temperature Compensation
Battery over-temperature protection.................
Tested and approved by and conforms to
EN 60335-1
EN 60335-2-29
EN 55014-1
EN 55014-2
PAH Testing
RoHS 2.0
IP67
(HU6525B)
(HU6540B)
148.6mm
105mm
User Manual
Dual Battery System & Solar Charger
In-Vehicle
DC-DC
Charger
HU6525/HU6540
12/24V Alerntor
11-32V
Max Temperature
85
º
C
Max Current
25A/40A
Solar MPPT
12/18/24V
Manufactured and Packaged for
Automotive Imports Pty Ltd
22 - 28 Lexton Road, Box Hill, Victoria, Australia
Made in China
AUS: www.hulk4x4.com.au NZ: www.hulk4x4.co.nz