PFC-50 & PFC-75 Charger Owner’s Manual Rev 2.
CONTENTS GENERAL OVERVIEW………………………………………………………5 KEY FEATURES LIST………………………………………………………. 6 DIMENSIONS AND SPECIFICATIONS…………………………………… 7 CHARGER OPERATION…………………………………………………….8 - Photo of Charger Face With Callouts…………………………………. 8 - Volts Trim ~ Adjusting the Peak Charging Voltage Limit………….. 9-10 - Reg Bus Port ~ Basic Info……………………………………………….. 11 - Descriptions of Panel LED Indicators………………………………… 11-12 - Dip Switches……………………………………………………………….. 13 WIRING YOUR MANZANITA MICRO CHARGER………………………..
READ THIS FIRST! ADDITIONAL NOTES AND PRODUCT MANUALS AVAILABLE AT: www.manzanitamicro.com CAUTION: Your PFC-Charger uses High Voltage DC and AC electricity. The chargers have been designed to be adaptable for use with many different battery types and voltages. It is the responsibility of the end user to properly set up the charger making necessary adjustments so that it can work with their unique system.
BATTERY NOTES! CAUTION: Your PFC-Charger can output over 400 volts DC and many thousands of watts of electrical power! It is imperative that the end user have a clear understanding of how to safely charge their particular battery! Manzanita Micro sells very flexible charging systems that can be used with almost any type of battery. Manzanita Micro chargers are used in all sorts of applications.
PFC-50 / 75 BATTERY CHARGER MANUAL Rev 2.1 General Overview The Manzanita Micro PFC chargers are a unique group of powerful, efficient battery chargers. The chargers will run off 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. Every model is user adjustable to charge batteries from 12 to 450 Volts DC.
PFC-50/75 SERIES CHARGER FEATURES •Power Factor Corrected •Every charger easily runs on any single phase AC voltage from 100 to 240V •Easy ‘Amps’ adjustment knob allows users to quick-tune the charger to pull maximum amps out of whatever it is plugged into •User adjustable peak charge voltage allows users to adapt charger to any battery voltage from 12 to 450 volts •Up to 18,000 watts of power from a unit that weighs less than 50 lbs (22kg) •Reg bus port for easy integration with Manzanita Micro BMS (also
Dimensions and Specifications The PFC-50 and 75 series chargers weigh approximately 42 pounds (19 kg) The outermost dimensions including foot flanges and front amps knob are approximately 22” L x 12.5” W x 7” H (559mm x 318mm x 177mm) Allow at least 25” total length (635mm) to include the power cables Input Voltage Range : 100 to 240VAC 40-80Hz computer grade pure sine wave Output Voltage Range : 12 to 450VDC ( +/- 1 volt ) Operating Temp Range : -20° F to +120° F ( -28.8° C to +48.
best and stainless steel or other quality plating is preferable to decrease corrosion. Charger Operation figure 02. Charger Layout (see final section for new 8A layout) Turning the Charger On and Off There is an ON/OFF Breaker to the left of the blue user control panel at the top of the charger. 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.
User Control Panel The user interface panel is the long blue panel with yellow text near the top of the PFC charger. The main things most users need to 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.
VOLTS TRIM CALIBRATION: 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. 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.
“REG BUS” 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. For more information on the specific reg bus pins refer to the “Reg Bus Wiring” section later in this manual. NOTICE! If your vehicle is equipped with a Battery Management System, ensure that the reg bus data cable is fully plugged into the charger whenever the vehicle is charging.
“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 shouldn’t need any adjusting but if the user were to have it set at 35 amps and then plug into a 15 amp 120V outlet it will quickly open a circuit breaker or fuse on the AC line. The vehicle operator may wish to adjust this knob when the charger is plugged in to a public outlet especially if there is no easy access to the electrical panel for that circuit.
If the switch is at ‘0’ then the timer will time out instantly - do not use this setting. (‘0’ is the 3-o-clock position when viewed from the front). If the switch is at ‘1’ it will go for 15 minutes before completely cutting back power. Each additional tick after ‘1’ adds 10 more minutes to the charge cutback time. Turning the switch clockwise all the way around to the 2:30 position will give the maximum amount of time.
NOTE: In mid 2010, a new 4 pin RJ receptacle was added to the front of the charger allowing for various preset voltage and current levels. For more information please refer to the 8A Control Board section at the end of this manual. Wiring your Manzanita Micro Charger A PFC-50 or PFC-50B charger built before 2011 should have two main power cables coming out of the front of the case (as shown in figure 02).
figure 05 : Example DC Power Cables Now you should have a blue SB-175 connector with a positive and negative wire coming out. (See figure 05) Use the appropriate size lug or connector for your battery terminal and crimp or solder it onto the other end of each cable. In order to reduce the likelihood of cable damage from corrosion, it is recommended to use a closed end tinned copper lug as opposed to an open end lug.
PFC-75 Pack Wiring Looking at the back of a PFC-75 charger or post 2011 PFC-50, you will see that there are five individual Anderson Power Pole connectors. There is a black and a red one next to each other on the top which is the DC output end of the charger. For your convenience a red and a black Power Pole connector have been included with your PFC-75. The red connector is for battery positive and the black connector is for battery negative.
figure 07 Rear Power Pole Charger Connections Connecting the Charger to the Wall Looking at the front of a pre-2011 PFC-50 the charger you will see that the top cable is labeled AC and it is the incoming power for the charger. Looking at the rear of a PFC-75 or other late model charger you will see 3 Anderson Power Pole connectors beneath the two DC output connectors.
changing between outlets of different voltages. The only thing which may need adjustment on the charger is the big “Amps” knob on the front. Turn this knob up or down depending on the amperage available from the outlet. With the “Amps” knob in the most clockwise position a PFC-50 can draw up to 50 amps and a PFC-75 can draw up to 75 amps. EXAMPLE: A PFC-50 plugged into a standard 120V outlet at 15 amps would be able to draw about 1,800 watts (120x15 = 1,800).
30, 10-40 or 6-50), use a 14-50 receptacle and simply disregard the middle straight neutral prong. Run the green wire to the ground prong and then the white and black wires to either of the two hot prongs. Since there is no neutral in the older 3 prong 220/240V plugs simply disregard the fact that your PFC charger has a 4 prong plug on it. Running Your PFC Charger on DC instead of AC You may have heard that Manzanita Micro chargers can run from both AC and DC power.
figure 08.
Reg Bus Wiring The Reg Bus Interface: The REG BUS communicates to the charger when any BMS regulators are regulating and also if any regs are too hot. The charger uses this information to determine when to turn down the charge current and when to turn off the charger. The interface contains six wires connected with their respective pins as follows: 1. WHITE : Power supply (+5 volt DC) 2.
How hot to run the regulators during the final absorption phase of charging is a function of the ambient temperature and how fast the vehicle needs to get back into service. Higher temperatures will make the absorption phase take less time but is more risky to the regulators. When the upper thermal threshold on a regulator has been reached, the reg will pull the hot reg line to +5 volts. This will tell the charger to stop charging until the temperature of the heat sink drops below the thermal limit.
figure 09. 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 hand to complete the crimp.
figure 10. 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’ and ‘WARN’ indicators.
NOTE: If an attempt is made to activate more than one of the voltage channels at the same time, the pin that was first activated will be the only channel that is active. NOTE: Because the 4 pin RJ port is mounted to the bottom of the control board the pin count reads from right to left as if backwards (see figure 11). figure 11.
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-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. This makes it very easy to adjust the big amps knob to safely get the maximum number of amps out of whatever you're plugged into.
For more information visit: www.manzanitamicro.
