a.
As always with HV wiring, observe necessary precautions
i.
Wear protective goggles & rubber sole shoes
ii.
Try not to use both hands at the same time (to reduce the possibility to run any currents
through your body)
iii.
Treat every HV terminal / wire as live even if you ‘know’ it’s not energized.
b.
OBSERVE POLARITY on battery connection! Wrong polarity will result in extensive damage to
the charger and significant fire hazard.
c.
VERY IMPORTANT: on your first battery connection, use the included inrush resistors in
series to reduce the initial inrush current to charge the caps inside the charger.
i.
There will still be a visible spark on the first connection – be prepared for it.
ii.
If you fail to use inrush resistors on the first connection, the spark will be much more
dramatic and the inrush current can easily blow up the internal capacitors in the unit
iii.
After a few seconds, disconnect the battery, remove inrush resistors, and reconnect the
battery back to the charger. Make sure you do all this in <30 seconds to not allow the
internal caps to discharge too much
d.
If your charger will be mounted in the vehicle and always connected to the battery, you do not
need to do anything else.
e.
If the charger will be disconnected and re-connected to the battery often, you will either need to
perform the above procedure every time or install an optional pre-charge circuit on the output. The
simplest precharge circuit would consist of the same pair of precharge resistors with a relay (rated
for the output current of the charger) across them. The relay will have to be driven by D5-HC
output on the control board. This will ensure relay closes as the charge starts and thereby bypasses
the inrush resistors.
6.
Connect AC wiring to the unit – observe markings on the unit. Incorrect connection WILL damage the
charger.
7.
Plug in the AC wiring into mains. In a few seconds, the fans should spin up. If they don’t, we advise you
to NOT PROCEED
8.
If you have already configured the charger (see appropriate step below), you can let it time out (5
seconds). Similarly, if you have already set the charger power in one of the previous runs, you can let the
next screen time out, as well (10 sec). Essentially, once your charger is fully configured, you do not need
to do anything on the next power-up – after 20 sec timeout, the charger will proceed with the parameters
from the last run (stored in non-volatile EEPROM).
9.
[To be performed ONLY ONCE for a given battery pack] The first thing you will see on each power-up is
an EMW greeting on the screen. If this is the first time you run the charger, press any button during the 5-
second countdown to set up your battery parameters. The series of screens will follow, allowing you to set
up (one of the buttons is used to cycle through values, another – to confirm selections):
