18
Fault Finding | Troubleshooting
Firstly, ensure the Pro Batt Ultra (BB) is wired up as per
page 6 / 7. Ensure negatives are common and the BB
charger’s negative is connected to the starter battery’s
negative - avoid connecting to chassis negative.
Voltages between common negatives should be ~0V.
Secondly, to test the BB, remove (or turn off) any
secondary charging source like AC to DC battery
chargers or solar chargers going to the battery banks.
Leave the primary charger connected (alternator) -
ensure alternator is working. We also recommend
turning off any loads (inverters etc.).
How to test if the Pro Batt Ultra (BB) is charging:
With engine running (alternator charging), what is the
voltage on the input terminal of the BB? What is the
voltage on the output terminal of the BB? Measure these
voltages at the BB’s terminals, not at the batteries
terminals.
Even though, by default, the BB can work down at 12.0V
on the input; it still requires over 13.5V+ to turn on and
get going. If you are getting alternator voltage at the
input terminal (~14V) and 14V+ on the output terminal
the chances are your BB is working fine. If little to no
current is passing through the charger at these voltages
then the batteries are either full or they are deceased. If
the output voltage is between 13V-14V (but rising) then
you could have a situation where the output batteries
were very low in charge (or large in capacity) and the
charger shall be charging at maximum current. Provided
the voltage continues rising the BB is charging.
If your output voltage is less than 13V and your input
voltage is healthy, it could be three things:
1) You have a large load on your output bank - turn load
off.
2) The BB has been turned off - hold SELECT button for
10 flashes and let go, to turn on again.
3) The BB is not working.
If your input voltage is less than 13V, it could be
several things:
Automotive:
Your alternator’s voltage is at
less than 13V (the alt. is regenerative braking mode -
sometimes expected on modern Euro 5/6+ engines) -
take vehicle for drive and measure alternator’s voltage
and set up the BB to suit these needs. All vehicle
manufactures have their own software / characteristics
for regen. braking.
Automotive or Marine:
If your alternator’s
voltage is ~14V then check continuity between the
alternator’s B+ terminal and the starter battery. If you are
getting ~14V on starter battery then check continuity
between starter battery and BB input terminal.
Automotive or Marine:
If your alternator’s
voltage is 0-13V (starter battery voltage) then alternator
may have failed. Or, requires increase rpm of engine,
possible belt slip. Or, your alternator current rating is
lower than the rating of the BB. Possibly set BB to half
power mode. You need a larger alternator.
Is your output voltage slightly higher or lower than
expected - even with no loads / chargers on?
Check if you have the temperature sensor connected.
If so, no problems leaving it there, it is simply voltage
compensating for when the temperature at the sensor
is lower or higher than the benchmark 20DegC (69F).
If lower, then the voltage shall rise and vice versa. The
further from 20DegC in either direction leads to
proportional increase or decrease in the voltage.
Possible, voltage drop across long cabling / fuse
holder / diode. Use our remote sense connection on
the unit - refer to page 6, yellow wire.
LED 16
flashing red - over voltage on input. This LED
comes on if there is 19V for more than 3 seconds on
the input terminal. Check the voltage at the input.
Possible regulator fault, or alternative charger’s
voltage is too high.
LED 16
solid red - Over voltage output. There is 16V+
for more than 3 seconds on output terminal. Check the
voltage at the output. Turn charger off, if voltage drops
when off and rises again when turned on the possible
charger fault. If 16V+ irrespective of charger being on
then check alternative charging source.
LED 17
flashing red - over temperature. Unit has
become too hot and switches off. Possible defective
fan. Or, high ambient temperature, ensure good
ventilation or the charger’s vents may be blocked
LED 21
flashes yellow - high voltage drop across
output cable. When the battery voltage sensor is
connected the device has detected too high a voltage
drop between the output and the positive terminal of
the battery (>1.5V). Verify that the cable thickness is
sufficient. Possibly the terminals are corroded or bad
connection. Also check if the cable is actually
connected to the battery.
LED 22
solid yellow or flashing - the charger is in 1/2
power. It has either been manually forced into 1/2
power mode or night mode (refer to page 11-13 ). Or,
the charger has engaged1/2 power mode itself due to
the device’s temperature (> 85°C). In this case, check
the fan and the ambient temperature. Possibly the
installation is not properly ventilated. Make the
adequate ventilation.
LED 23
solid yellow or flashing - undervoltage. If the
LED flashes, the input voltage is too low. Check the
alternator or the charging source of the starter battery.
If the LED is solid, the output voltage is very low -
output batteries are likely to be defective.
LED 24
flashing red - high battery temperature. The
unit has shut down due to excessive battery
temperature (> 55°C). Either the battery is defective or
the ambient temperature is too high. Provide adequate
ventilation.
