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BATTERY CHARGER PFC-20
PFC-30
&
PFC-40
Series Chargers
Owners Manual
Rev 0.4
©2008 Manzanita Micro
The information date is: 05/21/2008 PFC-20/30/40 SERIES
BATTERY CHARGER
MANUAL rev 0.4
General Overview
The Manzanita Micro PFC-## chargers are a unique group of powerful, efficient
battery chargers. The chargers will run off of any voltage from 100 up to 240 AC
These chargers can be set to run automatically when plugged in yet they also have
far more user adjustable functions than other electric vehicle chargers. Every model
is user adjustable to charge batteries from 12 to 450 Volts. All the chargers are
power factor corrected and are available with enhanced options such as an AC input
current display. With so much flexibility and models from 20 to 75amps your PFC
charger may be the last charger you ever need to buy.
Speed and Efficiency
The essential ingredient for fast recharge times is to deliver high power to the
battery. The key to polite opportunity charging is to be able to share outlets with
other equipment and make efficient use of limited current. The PFC line of chargers
have an adjustable throttle knob to allow the chargers to be turned down to operate
on very limited power sources. Efficiency and power factor are both better than 0.9.
What does the PFC mean?
In the Manzanita Micro chargers PFC stands for Power Factor Corrected. This
means that current and voltage are drawn in unity, (ie: current is drawn with unity to
the incoming line voltage).
Dimensions and Model Ratings
The PFC-20, PFC-30 and PFC-40 series chargers weigh in at approximately 18
pounds and reside in a box that is 13 x 9 x 5.5 inches.
The 20, 30 or 40 nomenclature is indicative of how many amps that charger is rated
to draw from the AC line. Unlike some other chargers this is the rated continuous
load and all the chargers are thoroughly tested to their rated limits before leaving
Manzanita Micro. An optional panel mount current meter is available which displays
the amount of current (amps) that the charger is drawing off of the AC line. This
allows the user to tune the charger precisely for the maximum allowable amps for
the outlet they are plugged into. Charger Operation
figure 02: PFC-##M Layout
Turning the Charger On and Off
There is an ON/OFF Breaker to the right of the cooling fan (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 disconnected while the
charger is putting out power the charger can be damaged. Failure to heed these
warnings may result in significant internal damage to the charger which is not
covered under your warranty! User Control Panel
The user interface panel is the long blue panel with yellow text near the top of the
PFC-XX charger. The only thing most users need be concerned with are the LED
indicators, the VOLTS TRIM and the adjustable AMPS knob. Below are
explanations of each feature in order from left to right. Refer to figure 02 for specific
locations.
VOLTS TRIM
This controls the peak DC voltage ceiling that the charger will allow the batteries to
reach before limiting the current. Unless specified otherwise, the voltage limit is
specifically calibrated and set by Manzanita Micro to 191 Volts (for a 156V nominal
pack.) In the event that adjustment is desired, please follow the instructions below.
NOTICE! Always use an appropriately sized insulated screw driver when adjusting
the voltage 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
VOLTS TRIM CALIBRATION:
Try to make sure your battery pack is fully charged before adjusting (or else you will
have to continually monitor it and make more adjustments).
1. Turn the amps knob all the way down (full counterclockwise).
2. Make sure the charger is plugged into the battery pack and that there are no open breakers or
open fuses in the DC battery circuit.
3.
With the chargers AC breaker switch in the OFF position, plug the charger into the AC power
outlet.
4.
Now turn ON the chargers AC breaker switch. The fans should come on.
5. Using an appropriate insulated screw driver, stick it into the VOLTS TRIM access hole and turn
the internal adjustment potentiometer until you find the threshold where the yellow LIMITS LED changes state. If the yellow LED is off, turn the trim pot counterclockwise to get it to
go 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 charge you will need to turn the trim pot clockwise to raise this voltage
ceiling. Then turn the AMPS knob up until you can put the amount of amps you want into
the battery pack while not letting the batteries go over their peak voltage limit according to
their manufacturers data.
While charging, when the battery pack voltage hits the peak limit the yellow LIMITS
LED will come on along with the flashing blue TIMER LED.
figure 03: VOLTS TRIM Adjustment
REG BUSS
This is the 6 pin RJ jack where the BMS communication line plugs into the charger.
This port allows the individual battery regulators to communicate with the charger.
NOTICE! If your vehicle is equipped with a Battery Management System, Ensure
that the reg buss data cable is fully plugged into the charger whenever the vehicle is charging. The communication data cables are hooked to the regulators in a daisy
chain fashion. Make sure that each of the smaller data cables are all plugged in
where they should be before charging. If there is an unplugged portion of the reg
buss, the charger cannot communicate with the regs and this could lead to
potentially damaging situation if there is an un-matched battery cell in the
pack! 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 RJ plug is
fully inserted and it should not be able to be pulled out without first pinching the
small plastic tab underneath the plug.
POWER - Green LED
The bright green POWER LED indicates when the charger is on. Input power
coming in and the main breaker is in the ON position.
WARN - Red LED
The red WARN LED should blink briefly when the charger is first powered up and
then remain off for the duration of the charge. If ever this indicator is on, turn down
the AMPS knob immediately, turn off the chargers breaker switch and consult
Manzanita Micro or a qualified service technician. This LED could indicate an over
voltage or over temperature condition. It could also be indicative of an open in the
pack. Turn down the AMPS knob and check to make sure there is no open in the
battery pack circuit. Check the gray SB-50 Anderson connector to insure that it is
connected and look for other disconnected battery cables. If the charger will not
work
NOTICE! DO NOT let the charger try to put current into the battery pack if there is
an open in the circuit. Never unplug the gray SB-50 Anderson connectors (DC line)
from your charger while it is charging! If the battery pack is disconnected while the
charger is putting out power the charger can be damaged. Failure to heed these
warnings may result in significant internal damage to the charger which is not
covered under your warranty!
AMPS Knob
The AMPS knob allows the user to adjust how much current the charger will move.
If the vehicle is always plugged in to the same circuit this shouldnt need any
adjusting but if the user were to have it set at 35 amps and then plug into a 15 amp
110V outlet it will quickly open a circuit breaker or fuse on the AC line. The vehicle
operator may wish to adjust this knob when plugged in to a public outlet especially if
there is no easy access to the electr