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Manzanita Micro PFC-20, Owner'S Manual, Page: 2 / 33

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Manzanita Micro PFC-20 Owner'S Manual Download Page 2

 

2 

CONTENTS 

 
IMPORTANT SAFETY WARNINGS.. 3 
 
IMPORTANT BATTERY SAFETY INFORMATION 4 
 
GENERAL OVERVIEW 5 
 

 

KEY FEATURES LIST. 6 
 
DIMENSIONS AND SPECIFICATIONS 7 
 

 

CHARGER OPERATION. 8 

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Photo of Charger Face With Callouts. 8 

- Volts Trim ~ Adjusting the Peak Charging Voltage Limit.. 9-10 
- Volts Trim using optional Digipot Push-Button Adjuster.. 10-11 
- Reg Bus ~ Basic Info.......... 12 
- Descriptions of Panel LED Indicators.....12-13 
- Dip Switches.. 14 
 

 

WIRING YOUR MANZANITA MICRO CHARGER.. 15 
- Connecting the Charger to the Battery Pack 15 
- Connecting the Charger to the Wall 16 
- PFC20 Wiring. 17 
- PFC30 Wiring. 17 
- PFC40 Wiring. 18 
- Running Your PFC Charger on DC instead of AC... 18 
- 120V Standard Adapter Drawing for PFC20 & PFC30. 19 
- 120V Standard Adapter Drawing for PFC40.. 20 
- Reg Bus Wiring & Pin-out Info.. 21 
- Reg Bus Cable Construction.....22-24 
- New 8A Control Board Additional Features...24-25 
- AC Line Power Meter Options....26 
- Optional Rear Control Port for Current Control or J1772...27 
- Remote Current Knob............................................................27-29 
- Older Charger Sheet Metal Front Image...............................29 
- Auto Restart Set Point Adjustment ..................................30-32 
 

 

CONTACTING MANZANITA MICRO.......................32 
 

 

 

 

 

 

 

 

 

 

Summary of Contents for PFC-20

Page 1: ...3 Manzanita Micro LLC The information date is 06 07 2013 Manzanita Micro reserves the right to alter product offerings and specifications at any time without notice and is not responsible for typographical or graphical errors that may appear in this document ...

Page 2: ...A MICRO CHARGER 15 Connecting the Charger to the Battery Pack 15 Connecting the Charger to the Wall 16 PFC20 Wiring 17 PFC30 Wiring 17 PFC40 Wiring 18 Running Your PFC Charger on DC instead of AC 18 120V Standard Adapter Drawing for PFC20 PFC30 19 120V Standard Adapter Drawing for PFC40 20 Reg Bus Wiring Pin out Info 21 Reg Bus Cable Construction 22 24 New 8A Control Board Additional Features 24 2...

Page 3: ...exposed high voltage connection points Use properly insulated tools to reduce the likelihood of the tool completing a current path 6 DO NOT USE A CONDUCTIVE METAL SCREW DRIVER TO ADJUST THE VOLTS TRIM ON YOUR CHARGER 7 When using a Manzanita Micro BMS with older charger models the regbus GND return line is NOT ISOLATED FROM MAIN BATTERY PACK NEGATIVE Never touch or create a path from the regbus co...

Page 4: ...RSON NEAR BY WHENEVER ONE PERSON IS WORKING WITH HIGH VOLTAGE NEVER TOUCH ANYBODY WHILE THEY ARE WORKING ON A HIGH VOLTAGE SYSTEM OR BATTERY PACK IF SOMEONE IS GETTING SHOCKED AND CANNOT LET GO OF THE ELECTRICAL SOURCE THE EXTRA PERSON CAN SAFELY DISCONNECT THE ELECTRICAL SUPPLY AND OR GET HELP IF IT IS NOT POSSIBLE TO DISCONNECT THE SUPPLY AND IF PROPERLY INSULATED EQUIPMENT IS AVAILABLE THEN THE...

Page 5: ...r you ever need to buy Speed and Efficiency The essential ingredient for fast recharge times is to deliver as much power to the battery as practical The key to polite opportunity charging is to be able to share outlets with other equipment and make efficient use of limited current The Manzanita Micro PFC line of chargers has an adjustable current throttle knob to allow the chargers to be turned do...

Page 6: ...e from 12 to 450 volts Up to 9 600 watts of power from a unit that weighs less than 20 lbs 9kg and is about the size of a shoe box Reg bus port for easy integration with Manzanita Micro BMS also compatible with other Battery Management Systems Self regulating thermal protection Active variable speed fan cooling Water cooling option Input line voltage line current wattage and power factor meter opt...

Page 7: ...menclature is indicative of how many amps that charger is rated to draw from the AC input power line Unlike some other chargers this is the rated continuous load and all units are thoroughly tested to their rated limits before leaving Manzanita Micro An optional multifunction panel mount meter is available which displays the amount of current amps that the charger is drawing off the AC line as wel...

Page 8: ...e Charger On and Off There is an ON OFF Breaker to the right of the front exhaust port or coolant fittings on liquid cooled models This breaker is the main switch to turn the charger on or off If ever there is a concern while charging first shut off this breaker switch NOTICE DO NOT unplug the gray SB 50 Anderson connectors DC line from your charger while it is charging If the battery pack is disc...

Page 9: ...ltage trim potentiometer Suitable drivers are available for purchase from Manzanita Micro or other electronics components manufacturers Mouser part 594 8T000 Vishay Spectrol Adjust Tool www mouser com figure 03 Adjustment Tool 008T000 NOTE If the battery pack is not heated for any reason such as outdoors in a cold climate the peak charging voltage threshold may need to be raised in order to assure...

Page 10: ...re the yellow LIMITS LED changes state If the yellow LED is off turn the trim pot counterclockwise to get it to turn on If the yellow LED is on turn the trim pot clockwise to get it to go off Once you find the threshold where the LED changes states the cutoff voltage is set to the actual battery voltage and the charger will not charge the pack above this voltage Therefore when you are ready to cha...

Page 11: ...imum safe voltage level for the customer s given scenario The optional digipot makes it very easy to adjust the peak voltage set point therefore it is up to the user to check and make sure that no person or thing changed the voltage setting to a level inappropriate for the battery pack being charged The digipot displays the approximate peak voltage set point level reading from left to right So in ...

Page 12: ...ere they should be before charging If there is an unplugged portion of the reg bus the charger cannot communicate with the regs and this could cause overcharging and potential fire The RJ connectors are similar to phone cord connectors and they are designed to snap into place and stay connected If a cable is disconnected insure that it is fully reconnected An audible click should be heard when the...

Page 13: ...s reached its peak voltage limit This should happen only at the end of the charge cycle when all the batteries are fully charged The LIMITS indicator should be accompanied by the blinking blue TIMER LED which indicates that the charger is in current cutback mode and the timer is counting down to the end of charge If the yellow LIMITS LED is blinking then it is indicating that there is an over temp...

Page 14: ...erstand these switch features before changing them Pull switches down to turn them on The image above shows the factory preset positions NEVER CHANGE DIP SWITCH 4 IT MUST REMAIN ON Dip Switch Guide 1 Engages timer at peak voltage limit set point This switch should be ON If the pack drops below the peak voltage limit the timer will turn off again 2 Starts timer as soon as the charger is turned on T...

Page 15: ...SB 50 connector has clearly marked positive and negative sides Of the three DC wires coming out of the charger white is positive black is negative and green is an optional vehicle chassis ground connection Measure the distance from your most positive battery terminal to your PFC charger s SB 50 connector Cut a 6 AWG or thicker cable to the appropriate length and solder or crimp the appropriate siz...

Page 16: ...ect it onto the other end of each cable Connect the positive cable to the most positive terminal of the battery pack Connect the negative cable to the most negative terminal of the battery pack Double check that the polarity is correct and then plug the battery pack SB 50 into the DC output SB 50 coming from the PFC charger see figure 08 Now the charger is connected to the pack and you are ready t...

Page 17: ...r on DC instead of AC section later in this manual NOTE The brass stud in the rear of newer chargers should be connected to the vehicle chassis to ensure a solid ground connection This stud can be seen in figure 15 which is toward the end of this manual Ohm s law states that Volts x Amps Watts of power and there are a certain number of Watt Hours stored in your battery pack and available to power ...

Page 18: ... AC input cable Please leave this attached and make adapter cords if you intend to change what it plugs into To attach the PFC 30 s input cable to a common 110 120V three prong 5 15 or 5 20 plug purchase a 14 30 receptacle and make an adapter exactly as shown in figure 09 If you wish to make an adapter cord to connect your PFC 30 s input cable to a 220 240V three prong plug like a NEMA 10 30 10 40...

Page 19: ... power and it is damaged repair work will likely NOT BE COVERED UNDER WARRANTY It should be noted that the primary on off circuit breaker on the charger is only AC rated For this reason we recommend installing an appropriate DC rated breaker or fuse on the input side when powering any Manzanita charger with DC There are two Manzanita Micro PFC charger models which can be run from DC power without ...

Page 20: ...20 figure 09 PFC 20 30 Adapter Wiring ...

Page 21: ...21 figure 10 PFC 40 Adapter Wiring ...

Page 22: ... any other non Manzanita Micro devices All measurements are made relative to the GND wire It is important to verify all six of the wires are continuous throughout the system and pin to pin AGAIN DO NOT USE THE REGBUS 5V POWER TO POWER ANYTHING ELSE NOTICE On older models the Ground GND on the reg bus is also battery negative on a PFC charger The primary functions of the REG BUS are 1 Supply power ...

Page 23: ...e cable in order to avoid errors from broken internal wires Additionally follow the proper cable construction techniques listed below and make sure that all the wires are installed in the correct orientation See figure 11 Proper Reg bus cable construction is not difficult but it requires keen attention to detail on the part of the person installing the plug ends onto the RJ cable The following ste...

Page 24: ...imping tool all the way with your right hand to complete the crimp If you have a clear plug end you can look in and make sure that each of the 6 metal pins sank all the way down into their respective wires Give the connector a slight tug to make sure that it is adequately fastened and now you have created a proper reg bus RJ cable end Follow the same steps on the other end of the cable and you are...

Page 25: ...he main default peak charging voltage channel A The new functions attached to the new 4 pin RJ connection can be controlled as follows 1 Pin 1 is for voltage channel B If 12 volts is applied to pin 1 using pin 4 as the ground then the charger will accept the peak voltage setting of the RV7 pot 2 Pin 2 is for voltage channel C If 12 volts is applied to pin 2 using pin 4 as the ground then the charg...

Page 26: ...o activate PIN 3 OPTIONAL AMPS ADJUSTMENT 12V to activate PIN 4 GROUND RETURN LINE VR3 MAIN AMPS ADJUSTMENT POTENTIOMETER RV9 OPTIONAL AMPS ADJUSTMENT POTENTIOMETER NOTE A four pin RJ plug must be used instead of the regular six pin that is used for the reg bus The four conductor wire is fairly easy to find as it is used for telephone cord If using pre made cords carefully observe the wiring color...

Page 27: ...n automatically This advanced meter provides very useful information for gauging power usage and efficiency levels under various charging circumstances It also gives users an idea of how good the power source is that they are plugged into The Power Factor PF function provides an idea of system efficiency Best case would be a PF of 1 00 Manzanita Micro chargers will display a higher power factor wh...

Page 28: ...ntrol knob on the front of the charger By being able to adjust the charger s input amperage the user can quickly turn the charger down when plugging into a standard 15A 120V wall outlet and then easily turn it up to pull maximum power from an RV outlet or Level 2 public charging station The optional Manzanita Micro Remote Current Knob or RCK now enables users to bury the charger deep in the vehicl...

Page 29: ... is also off In the OFF state the PFC Charger s own current control knob will provide the means for amperage adjustment When the toggle switch is in the ON position it is pointing away from the knob and the green LED is illuminated While in the ON state the RCK will provide the means for amperage adjustment Full counter clockwise is no current and full clockwise is full current When the RCK is ena...

Page 30: ...figure 17 Remote Current Knob Older Charger Front Image figure 18 Older Charger Layout Prior To November 2012 ...

Page 31: ...ed but plugged in for a very lengthy period of time and the attached battery pack could get to a dangerously low level or even go to zero volts The auto restart feature allows the charger to automatically resume charging even after a full time out if the connected battery pack reaches a certain voltage set point To enable the auto restart feature dip switch 8 must be in the ON position which is do...

Page 32: ...E WAY DOWN SO THERE IS NO CURRENT FLOWING WHEN THE DC OUTPUT IS DISCONNECTED 8 Double check that the battery pack is properly connected to the charger and that the pack is at the desired voltage level for the auto restart to initiate 9 Slowly turn the auto restart potentiometer VR6 clockwise to increase the voltage limit level at which the charger will auto restart Keep watching the charger s blue...

Page 33: ...red these may be communicated to Manzanita Micro prior to order completion Manzanita Micro can easily tune to specific levels for large orders of multiple units Additionally if the end user s battery pack is below 130V then the auto restart potentiometer VR6 will have to first be turned down low enough to allow the aforementioned auto restart setup procedure For more information visit www manzanit...

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