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POWERGUARD PRO
USER & INSTALLATION GUIDE
Revision: B
REF: QSF-030
Issue: D
Flat Battery Protection System
Merlin Equipment Ltd
Hill Barton Industrial Estate
Exeter, Devon, EX5 1SA
T: +44 (0) 1202 697979
Merlin Power Systems
332-4 West Montauk Highway
New York NY11946
United States of America
T: +1 (631) 594 5102
www.merlin-power.com
Merlin Equipment Ltd
PowerGuard Pro – User and Installation Guide
PC Interface
Battery 1
Battery 2
Time
Volts
Volts
Delay
L
H
L
H
0
L
Clyst Court
United Kingdom
Hampton Bays
Page: 1 of 18
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Summary of Contents for Merlin POWERGUARD PRO
- Page 1 Merlin Power Systems 332-4 West Montauk Highway Hampton Bays New York NY11946 United States of America T: +1 (631) 594 5102 www.merlin-power.com REF: QSF-030 Merlin Equipment Ltd Issue: D PowerGuard Pro – User and Installation Guide Page: 1 of 18...
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Page 2: Warning
Therefore not all obvious practices that may lead to system damage, injury or death are detailed within this manual. If you are in anyway unsure about any aspect of the installation or use of PowerGuard Pro, contact your Dealer or Merlin Power Systems for advice. -
Page 3: Precautions
• MAINTENANCE. If you have problems or suspect device failures DO NOT attempt to repair the unit yourself. Return it to your Dealer or Merlin for servicing. REF: QSF-030 Merlin Equipment Ltd Issue: D PowerGuard Pro – User and Installation Guide Page: 3 of 18... -
Page 4: Approvals And Conformity
CERTIFICATE OF CONFORMITY Declaration of Conformity Merlin Equipment Limited, hereby declares that the product marketed as P o w e r G u a r d P r o is in compliance with the requirements of EU Electromagnetic Compatibility (EMC) Directive 2014/30/EU. -
Page 5: Table Of Contents
INTRODUCTION Thank you for choosing Merlin PowerGuard Pro! PowerGuard Pro is a remote battery switching system. This allows you to mount battery master switches in convenient locations such as dashboards or helm panels without needing to run heavy duty cables throughout the vehicle/boat. -
Page 6: Identification Of System Components
IDENTIFICATION OF SYSTEM COMPONENTS PowerGuard Pro comprises a number of components. PowerGuard Pro is configured for 1 or 2 battery bank installations, at 12 or 24 Volt DC. A number of additional components (e.g. Contactors, Switches) may also be used in the system. -
Page 7: Installation
PowerGuard Pro main components (ECU & Contactors) do not need to be easily accessible from a user’s perspective. Only the control switch needs to be readily accessible to the user. The following should be observed as parts of the PowerGuard Pro are designed for wet / dirty environments, but others are not. -
Page 8: Ecu Installation
ECU INSTALLATION The PowerGuard Pro ECU is supplied with 2 Mounting Flanges. Each flange has a mounting slot to enable fitment of M5 bolts. Ensure that the unit is securely mounted to the vehicle using suitable bolts, washers and nuts. -
Page 9: Wiring Schematics
Ti m e Vol t s Vol t s Del a y System Loads Fuse Vehicle Alternator Fuse Vehicle Starter Motor Engine Battery REF: QSF-030 Merlin Equipment Ltd Issue: D PowerGuard Pro – User and Installation Guide Page: 9 of 18... - Page 10 If B1 and B2 are transposed, the system will not operate correctly. • Caution! Ensure always that the correct polarity is observed on the PowerGuard Pro wiring. Serious damage to the PowerGuard Pro ECU will occur if wires are shorted or connected the wrong way around.
- Page 11 CONTROL & SENSE CABLING: The PowerGuard Pro is supplied with 3 separate wiring looms generally as per the diagram below: Loom3 Input / Output Loom 3 Input / Output Loom 1 Loom 2 Loom 1 Loom 2 Battery 1 Battery 2...
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Page 12: Notes
IGNITION INHIBIT WIRE: Where the PowerGuard Pro is connected to an engine start / vehicle chassis battery, the Ignition wire (pink) MUST be connected to the engine’s ignition switch. When the ignition is on, PowerGuard Pro is disabled and will not disconnect batteries. The remote battery switches will not work. -
Page 13: Set Up And Adjustments
BATTERY CONNECTION: Connect the batteries. You will hear various clicks and clunks as the PowerGuard Pro determines the position of contactors. Depending on unit status the switch LEDs may light. DIGITAL SIGNAL PROCESSING: PowerGuard Pro senses and processes voltages using a Digital Signal Processing (DSP) which filters out transient spikes and electrical noise preventing contactors connecting and disconnecting erroneously. - Page 14 11.6 Vdc for disconnection voltage, 120 seconds for time delay. The flat battery protection setting is the threshold at which the PowerGuard Pro will disconnect the battery once the disconnect voltage has been reached and the time delay has elapsed.
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Page 15: Programming
LED Off = Manually isolated. Note: Uses green LED switch Should the end user require custom programming, the PowerGuard Pro can be supplied as an ECU only with external components as required. In this instance a ‘Specifying Guide’ will need to be completed by the specifying engineer. -
Page 16: Powerguard Pro Operation
Please ensure all programming requirements and parameters and any customer training needs are addressed by your specifying engineer before taking delivery of the unit. POWERGUARD PRO OPERATION PowerGuard Pro has been developed as a remote battery switching & flat battery protection system. During normal operation the... -
Page 17: Product Specifications
Cable Cap Insulation Boot 2 – 2/0 AWG Black HWC/FHMG/1 Mega Fuse Holder HWC/FME/200 200A Mega Fuse HWC/ATOF/KIT ATO Single Blade Fuse Holder HWC/BF5 5 Amp Blade Fuse REF: QSF-030 Merlin Equipment Ltd Issue: D PowerGuard Pro – User and Installation Guide Page: 17 of 18... -
Page 18: Warranty
If your product requires troubleshooting or warranty service, contact your merchant. If you are unable to contact your merchant, or the merchant is unable to provide service, contact Merlin directly at: Merlin Equipment Ltd, Clyst Court, Hill Barton Industrial Estate, Exeter, Devon, EX5 1SA, United Kingdom. Tel: +44 (0) 1202 697979.
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