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POWERBANK LITE
USER & INSTALLATION GUIDE
Revision: A
REF: QSF-030
Issue: D
Flat Battery Protection & Split Charge System
P2
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.merlinequipment.com
Merlin Equipment Ltd
PowerBank Lite – User and Installation Guide
JP1
P1
JP1
Clyst Court
United Kingdom
Hampton Bays
Page: 1 of 18
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Summary of Contents for Merlin POWERBANK LITE
- 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.merlinequipment.com REF: QSF-030 Merlin Equipment Ltd Issue: D PowerBank Lite – 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 PowerBank Lite, 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 PowerBank Lite – 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 B a n k L i t e is in compliance with the requirements of EU Electromagnetic Compatibility (EMC) Directive 2014/30/EU. -
Page 5: Introduction
PowerBank Lite is a complete power management system designed to facilitate both split charging and flat battery protection on two battery banks. PowerBank Lite 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: Table Of Contents
PROGRAMMING ........................14 POWERBANK LITE OPERATION ..................... 16 AFTER INSTALLATION ......................17 PRODUCT SPECIFICATIONS ....................17 PRODUCT ACCESSORIES ....................... 17 WARRANTY .......................... 18 REF: QSF-030 Merlin Equipment Ltd Issue: D PowerBank Lite – User and Installation Guide Page: 6 of 18... -
Page 7: Identification Of System Components
Standard contactors are rated at 200A continuous for both 12 & 24V systems. Control Switches: Illuminated rocker switches can be provided for the switched inputs into the PowerBank Lite ECU. These can be used to control the isolation contactors and to provide emergency connection of the split charge contactor. - Page 8 PowerBank Lite control status can be communicated to the user via the LEDs contained within the switch. Alternatively, external LEDs can be provided. Up to 4 Switches can be installed per vehicle as follows: Switch 1 - Toggle Engine Battery (1) Switch...
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Page 9: Installation
Warning! Isolate power supply before starting installation. POSITIONING OF PARTS PowerBank Lite main components (ECU & Contactors) do not need to be easily accessible from a user’s perspective. Only the control switches need to be readily accessible to the user. -
Page 10: Ecu Installation
ECU INSTALLATION The PowerBank Lite 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 11: Wiring Schematics
Battery • Caution! Ensure always that the correct polarity is observed on the PowerBank Lite wiring. Serious damage to the PowerBank Lite ECU will occur if wires are shorted or connected the wrong way around. • Caution & Warning! We recommend that appropriately rated fuses or circuit breakers are inserted between batteries and PowerBank Contactors to protect against short circuits. - Page 12 B2 Battery Isolator Positive 0.75mm Blue / Black Caution & Warning: PowerBank Lite switch supply wiring requires protection with a small inline fuse. This should be rated at 2A DC and used in every installation. REF: QSF-030 Merlin Equipment Ltd Issue: D PowerBank Lite –...
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Page 13: Notes
SWITCH CONNECTIONS: The PowerBank Lite is supplied with four momentary rocker switches. Two with red LEDs and two with green LEDs. The switches should be connected as follows: Switch 1 Switch 2 Switch 3 Switch 4 Ignition Switch Green Green... -
Page 14: Programming
The DSP operation means that the PowerBank Lite will take time to respond to sudden changes in voltage, so it may appear that there is a time-lag between the voltage reaching a certain level and the PowerBank Lite reacting to it. - Page 15 LED Off: No split charge is taking place. Note: LED 5 & 6 are not currently used. Should the end user require custom programming, the PowerBank Lite 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.
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Page 16: Powerbank Lite Operation
PowerBank Lite has been developed as a total battery management product for 2 battery banks. During normal operation the PowerBank Lite will monitor the voltages of both the engine and auxiliary batteries. Depending on these voltages it will carry out the following tasks: 1. -
Page 17: After Installation
AFTER INSTALLATION If you are unsure about any aspect please consult a suitably qualified engineer, your Dealer or Merlin Equipment Ltd before commissioning the unit. PRODUCT SPECIFICATIONS PowerBank Lite Part Number(s) 19-5110 (ECU Only) 19-5100 (12V 2 Batteries) 19-5101 (24V 2 Batteries) -
Page 18: Warranty
WARRANTY PowerBank Lite is warranted to be free of defects caused during manufacture for a period of 2 years from purchase. The warranty may be invalidated if the device has been altered, misused, installed incorrectly or operated in adverse conditions described in the “Precautions”...
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