Manzanita Micro PFC-20 Owner's Manual
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Manzanita Micro PFC-20 Owner's Manual

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PFC-20, PFC-30 &
PFC-40 Charger
Owner's Manual
Rev 3.1
©2013 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.
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Summary of Contents for Manzanita Micro PFC-20

  • Page 1 ©2013 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: Table Of Contents

    .. 12 - Descriptions of Panel LED Indicators .12-13 - Dip Switches .. 14 WIRING YOUR MANZANITA MICRO CHARGER .. 15 - Connecting the Charger to the Battery Pack - Connecting the Charger to the Wall - PFC20 Wiring . 17 - PFC30 Wiring .
  • Page 3 With such flexibility, the charger is intended to be able to be configured for use in various experimental applications and Manzanita Micro LLC and its employees, contractors and affiliates cannot be responsible for any damages due to any Manzanita Micro product that has been set up by the end user.
  • Page 4 Manzanita Micro chargers are capable of outputting any charging voltage from 12 to 450 volts DC. It is up to the end user to understand the safe voltage range for their particular battery, cell, battery pack or other energy storage device.
  • Page 5 REV 3.1 General Overview The Manzanita Micro PFC chargers are a unique group of powerful, efficient battery chargers. The chargers will operate on any voltage from 100 up to 240 volts AC. The chargers can be set to run automatically when plugged in, yet they also have far more user adjustable functions than other electric vehicle chargers.
  • Page 6 0 and 1. The closer to 1 the better. Manzanita Micro PFC chargers generally have a very high power factor number which means less wasted energy. PFC-20/30/40 SERIES CHARGER FEATURES •Power Factor Corrected •Every charger easily runs on 110/120V and 220/240V •Easy ‘Amps’...
  • Page 7 4pin RJ connection on the blue face plate Dimensions, Specifications and Mounting The PFC-20, PFC-30 and PFC-40 chargers weigh approximately 18 pounds (8.2 kg) The maximum outermost dimensions including foot flanges and protrusions are approximately: 14”...
  • Page 8 yellow limits light starts blinking and the charger's current cuts back, it is likely more airflow is needed. The fans push the air out through the front of the charger, therefore, mounting the unit such that the control face is pointing upward is probably the most efficient since heat rises.
  • Page 9 “fully charged” voltage specifications and how they might change based on temperature. NOTE: The peak voltage regulation set point on a Manzanita Micro charger is accurate to within 5 volts or less. Follow the “Volts Trim Calibration” instructions on the next page and make the initial adjustment with the amps knob completely down so that no current is flowing.
  • Page 10 Final tuning is best accomplished when the battery pack is fully charged. The lower the state of charge, the more the user will need to monitor and adjust the unit during the first charge cycle. Turn the amps knob all the way down (full counterclockwise). 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.
  • Page 11 Unless specified otherwise, the voltage limit is set by Manzanita Micro to 48 volts. In the event that adjustment is desired, please refer to Figure 05 and follow the instructions on the next page.
  • Page 12 If this indicator stays on, turn down the AMPS knob immediately, turn off the charger’s 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 circuit condition in the pack.
  • Page 13 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”...

  • Page 14: Dip Switches

    “TIMER ADJ” This stands for timer adjustment. This is a small 16 position rotary switch which allows the user to adjust the amount of time that the charger takes in constant voltage mode, while cutting back current at the end of a charge cycle before it shuts off completely.

  • Page 15: Wiring Your Manzanita Micro Charger

    8A Control Board section at the end of this manual. Wiring your Manzanita Micro Charger Your PFC-20, 30 or 40 charger has two main power cables coming out of the rear of the case (see final section for older models) The lower cable is for the incoming power (usually AC from a wall outlet) and the top cable is the charger’s DC output.
  • Page 16 figure 07: DC Battery Side User-Built Example Power Cable Now you should have a gray SB-50 connector with a positive and negative wire coming out. (See figure 07) Use the appropriate lug or connector for your battery terminal and connect it onto the other end of each cable. Connect the positive cable to the most positive terminal of the battery pack.

  • Page 17: Connecting The Charger To The Wall

    AC printed next to one of the cables and this is for the incoming power for the charger. A great feature of the Manzanita Micro PFC line of chargers is that they are capable of operating easily from 110,120, 208, 220, 230 or 240 volts of single phase AC power.

  • Page 18: Pfc20 Wiring

    With the “Amps” knob in the most clockwise position a PFC-20 can draw up to 20 amps, a PFC-30 can draw up to 30A and a PFC-40 can draw up to 40A.

  • Page 19: Running Your Pfc Charger On Dc Instead Of Ac

    Note: Any Manzanita Micro PFC-20, 30 or 40 charger can be plugged into a NEMA 14-50 outlet. The 50 amp rating is just what the outlet is capable of and the charger will only draw as much as it is designed to use.
  • Page 20 09. PFC-20/30 Adapter Wiring...
  • Page 21 figure 10. PFC-40 Adapter Wiring...
  • Page 22 The +5 and GND power comes from a 100 mA current limited power supply which should NOT be used to power 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.

  • Page 23: Reg Bus Cable Construction

    Adding airflow across the regulators will dramatically help cooling the regs and speed up charge equalization by allowing more dissipation. NOTICE! Manzanita Micro strongly advises air cooling of the BMS regulators for maximum dissipation capability and longevity of the reg. For more information on regulator cooling see the appropriate Manzanita Micro regulator manual for your BMS.
  • Page 24 figure 11. Correct RJ Cable Orientation Step 6: Double check that the blue wire is to the right side with the tang down and then take the RJ crimping tool in your right hand. With your left hand push the cable with un-crimped plug into the 6-pin die on the crimping tool. Step 7: While using your left hand to make sure that the RJ cable is firmly held all the way into the connector, squeeze the crimping tool all the way with your right...

  • Page 25: New 8A Control Board Additional Features

    12. Side View of Proper RJ Cable New 8A Control Board Additional Features Manzanita Micro improved the original charger control interface board and began integration into production models in mid 2010. If your charger is equipped with the new control board it will be evident by the new front faceplate which has an extra 4 pin RJ port in between the ‘POWER’...

  • Page 26: Ac Line Power Meter Options

    Manzanita recommends Tang Down BLACK to the Right for the 4-wire cable. AC Line Power Meter Options As of January 1, 2011 Manzanita Micro includes a regular AC current meter built into the front of all PFC-30, PFC-40, PFC-50 and PFC-75 chargers. This standard display allows the user to see in real time exactly how many amps the Manzanita Micro charger is drawing from the AC power source that it is plugged into.

  • Page 27: Optional Rear Control Port For Current Control Or J1772

    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 when they are running at full power. The PF rating also will tend to be at its best when charging a battery pack which is greater than or equal to the AC input line voltage.

  • Page 28: Remote Current Knob

    Manzanita Micro's special remote current knob (RCK) unit or by the Manzanita Micro Smart Box. The Smart Box, accepts and interprets the SAE J1772 communication signal from external EVSE devices such as those found in modern public charging stations. When the communication cable is plugged into this special...
  • Page 29 The operation of the RCK is very simple. Make sure the RCK cable is plugged in to the rear port on the Manzanita Micro PFC charger (the white arrow on the cable connector should line up with the white triangle on the charger's connector).When looking at the RCK's main control face, the toggle switch is on the left below the green LED and the amperage control knob is to the right.
  • Page 30 figure 17 : Remote Current Knob Older Charger Front Image figure 18. Older Charger Layout Prior To November 2012...

  • Page 31: Auto Restart Set Point Adjustment

    Auto Restart Set Point Adjustment Manzanita Micro PFC chargers both new and old have an auto restart function built in which can be activated and adjusted by the user. Because of the possibility of thermal runaway from a battery pack, module or cell that is over-charged, Manzanita Micro does not ship PFC chargers with the Auto Restart Switch enabled.
  • Page 32 Steps For Setting The Auto Restart Set Point 1. Unplug anything connected to either of the RJ data ports on the front of the charger. (This includes unplugging even any Manzanita Micro BMS from the reg bus port. 2. SET THE MAIN VOLTS TRIM TO YOUR PEAK OUTPUT LEVEL FIRST!!! 3.
  • Page 33 NOTE: A new charger's auto restart level is usually set to somewhere around 130 VDC before shipping from Manzanita Micro. If certain rates are desired, 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.

This manual is also suitable for:

Pfc-30Pfc-40

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