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F) AC Input Wiring
NOTE: (For marine applications) THE INSTALLATION
AND PROTECTION OF VESSEL WIRING ASSOCIATED
WITH BATTERY CHARGERS SHALL COMPLY WITH ABYC
STANDARDS E-11) AC & DC ELECTRICAL SYSTEMS ON
BOATS, AND A-31) BATTERY CHARGERS & INVERTERS
These models are provided with an IEC certified AC cord
which may be plugged into the charger and a proper
outlet. If the plug is not suited to the available outlet, 1)
obtain an IEC cord with appropriate plug or 2) obtain the
correct plug for the outlet and install it on the provided
IEC cord. When installing the plug, pay careful attention
to the pin wiring as follows:
Brown...................................................AC Hot (fused)
Blue.....................................................AC Neutral
Green (or Green with Yellow Stripe...AC Ground (safety/
earth)
As shipped from the factory, the AC input is "universal"
and will accept AC voltage in the range of 90-264 VAC,
47-63 Hz.
A power cord cable clamp has been provided to prevent
accidental disconnect of the AC cord. After the plug has
been inserted into the charger, snap the pre-formed clamp
around the AC input cable as close to the insertion point
as practicable and use a screw to fasten the clamp tightly
to the wall or bulkhead on which the charger is mounted.
Hard Wiring AC Input
If desired, the AC input to your charger may be hard-wired
directly to the AC distribution panel. Install the charger
end of the provided input cord as described above, then
cut off the plug and splice onto three conductor marine-
grade cable with crimp but connectors, observing color
codes and fuse/circuit breaker ratings as above. For all
models, use minimum 16 AWG cable.
All charger wiring should be made in accordance with
UL, U.S. Coast Guard and/or ABYC regulations and
recommendations, as well as all relevant local codes.
See REFERENCE APPENDIX for sources.
AC input for the charger must be plugged into an
appropriate, over-current protected three prong outlet
OR routed through a separate dedicated fuse or circuit
breaker on an AC distribution panel with proper safety/
earth chassis ground in accordance with all local codes
and ordinances.
CAUTION (230 VAC applications only): If AC input is
derived from a source consisting of two HOT leads (phase-
to-phase 230 VAC input voltage), an external fuse or circuit
breaker must be used to protect the unfused (formerly
NEUTRAL, now HOT) lead.
A note about the AC Input Fuse: The AC input of your
charger is protected by an input fuse located inside the
unit. Due to the current limiting characteristics of the
charger, it is highly unlikely that this fuse will blow unless a
malfunction occurs within the charger. The fuse is not user
replaceable. Replacement of the fuse must be preformed
by a qualified service person.
All charger wiring should be made in accordance with
UL, U.S. Coast Guard and/or ABYC regulations and
recommendations, as well as all relevant local codes.
See section IX) REFERENCE APPENDIX for sources.
IV) OPERATION
A) Three Stage Charge Regimen
The Phase Three Battery Charger features the three stage
charge regimen which is widely recommended by battery
manufacturers for allowing the fastest possible recharge
time without loss of batteries' electrolyte (gel or liquid) which
may be caused by sustained charging at higher voltages.
This three stage regimen is initiated each time AC is first
applied, when drained batteries are most likely to be
encountered. The regimen proceeds as follows:
1) Bulk Charge – When batteries are significantly discharged
the charger responds initially by delivering a high amount
of DC current, at or near the charger's maximum rated
output, in order to rapidly replenish them. It is during this
stage that charging current is maintained at a high level
as battery voltage increases. Bulk charging continues until
battery voltage reached the "charge" voltage level (where
batteries are at about 75-80% of capacity). A current limit
circuit prevents charger overload during this maximum
output stage
2) Absorption Charge – During this second stage of
the charge cycle, battery voltage is maintained at the
"charge" voltage level. Output current begins to taper off
as the battery plates become saturated. Charge voltage
is maintained until the current sensing circuit detects
that output current has tapered to about 5-15% of charger
rating*. At this point, the batteries are at about 95% of full
charge and the Phase Three charger switches to the third
and final stage of the charge cycle.
*Note: The absorption phase may also be ended by the
time-out circuit. See section B following for a complete
explanation of the purpose and functioning of the time-
out circuit.
3) Float Charge – For extended battery life, the Phase
Three then automatically switches to a lower float voltage
level. This float charge keeps batteries at peak condition
without overcharging. The charger may be left in this
stage for months without attention (though periodic checks
of electrolyte level in flooded batteries is recommended.)
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