Charles 93-IMC80-A, 93-IMC100-A, 93-IMC120-A Owner's Manual

LT‐IMCHRGR120‐1Issue 1 Print 2

IMC Series

Intelligent Battery Charger

INSTALLATION INSTRUCTION

& OWNER’S MANUAL

Model 93-IMC80-A

93-IMC100-A 93-IMC120-A

LT-IMCHRGR120-1 Issue 1 Print 2

INTRODUCTION AND APPLICATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Purpose 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT SAFETY INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environmental Precaution 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location Precautions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Precaution 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Damaged Unit Precaution 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly Precaution 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance/Cleaning Precaution 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Safety Precautions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing to Charge Precautions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding Precautions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOUNTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Recommendations 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection Points 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMC Series OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger Terminology 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Soft Touch Button Setting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turning the IMC Seriest ON/OFF 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Mode 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Types 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure for Setup Mode 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Notes 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration Storage 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Screens 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Display Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lamp Test Mode 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling and Blower Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALARMS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarm Silence 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deeply Discharged Battery Recovery 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Temperature Compensation During Charging 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIMP HOME MODE 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTAINING THE IMC Series 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMC Series FAILURE AND REPLACEMENT 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY AND SERVICE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Center and Repair Correspondence 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FACTORY DEFAULT SETTINGS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LT‐IMCHRGR120‐1Issue 1 Print 2

INTRODUCTION AND APPLICATION

Thank you for purchasing the IMC Series™. We hope you will be satisfied with this charger and it provides many years of exceptional service.

The IMC Series™ is a heavy duty, state of the art, microprocessor controller, four bank Battery Charger that allows easy custom user configuration and setup.

This charger has the following features that make it configurable to fit most applications.

 Can charge four battery banks  Bright Vacuum Florescent Display (VFD) to indicate information such as output amps, battery

voltage, temperature (Celsius or Fahrenheit) and alarms

 12 or 24 VDC output (user selectable) by battery bank  Pre−configured for Gel, Flooded Lead Acid, AGM or NiCAD batteries. (or adjust and modify the

preset configuration to meet your needs).

 Universal AC input (120/240 VAC, 50/60 Hz) automatic voltage selection  Available in 20, 40, 60, 80, 100 & 120 amp sizes  Memory button that stores all settings and can be transferred to other chargers in case of failure or

upgrade.

 Audio Alarm (user selectable: On/Off)  Soft Touch Capacitive User Interface that is resistant to dust and dirt contamination.  Double heavy duty Form C alarm battery contacts  Equalization (Flooded Lead Acid and NiCAD only)  Deeply Discharged Battery Recovery system to safely recharge a deeply discharged battery.  “Battery Reversed (automatic shutoff)… no fuse blowing.” (indicator and relay)  Cool touch, rugged case with retained screws on the covers  −20 to +55 C (−4 to 131 F) ambient operating temperature with no derating  Over Temperature detection and shutdown (prevents damage due to overheating)  Optional fully functional Remote display with keypad and Audible alert  Optional easy to install Battery Temperature Sensors for each battery bank

Manual Purpose

With your personal safety in mind, this manual lists important safety precautions first, then covers installation, operation, maintenance, troubleshooting, warranty, and service information.

IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions

for the IMC Seriest. Read the entire manual before usage.

LT-IMCHRGR120-1 Issue 1 Print 2

DANGER

To avoid serious injury or death from high voltage electrical shock disconnect AC shore power before opening panel.

DANGER

Pour éviter la blessure ou la mort sérieuse de la décharge électrique à haute tension, débrancher le pouvoir de rive de courant alternatif avant d'ouvrir le panneau.

WARNING

RISK OF EXPLOSIVE GASES! WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. THEREFORE IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR IMC Seriest YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.

To reduce risk of battery explosion, follow these instructions, those of the battery manufacturer, and the manufacturer of any equipment you use in the vicinity of the battery. Review cautionary markings on these products and on the engine.

AVERTISSEMENT

LE RISQUE DE GAZ EXPLOSIFS ! LE FONCTIONNEMENT A PROXIMITE D'UNE PREMIERE PILE ACIDE EST DANGEREUX. LES PILES PRODUISENT DES GAZ EXPLOSIFS PENDANT L'OPERATION DE PILE NORMALE. DONC C'EST D'IMPORTANCE D'UPMOST QUI CHAQUE FOIS AVANT D'UTILISER VOTRE COLLECTION D'IMC VOUS LISEZ CE MANUEL D'UTILISATION ET SUIVEZ LES INSTRUCTIONS EXACTEMENT.

Pour réduire le risque d'explosion de pile, suivre ces instructions, ceux-là du fabricant de pile, et le fabricant de n'importe quel équipement que vous utilisez à proximité de la pile. Réexaminer des marques d'avertissement sur ces produits et sur le moteur.

Environmental Precaution

The IMC charger is intended for installation in an area protected from rain and/or snow.

Location Precautions

When choosing a location for the IMC Series the following precautions must be adhered to:

1. Locate the IMC Series as far away from the battery as DC cables will permit.

2. Never place the IMC Series directly above the battery being charged; gases from the battery will corrode and damage the IMC Series.

3. Never allow battery acid to drip on the IMC Series when reading gravity or filling the battery.

4. Do not operate the IMC Series in an enclosed area or restrict ventilation in any way.

5. Do not set a battery on top of the IMC Series.

6. This battery charger should be installed so that it is not likely to be contacted by people. Don’t touch the top of the IMC charger when operating, hot temperatures present a risk of burns.

Application Precaution

These units are intended for hard-wired, permanent, installation. Use of attachments not recommended or sold by the Charles Marine & Industrial Group may result in risk of fire, electrical shock or personal injury.

LT‐IMCHRGR120‐1Issue 1 Print 2

Damaged Unit Precaution

Do not operate the IMC Series if it has received a sharp blow, been dropped, immersed in water or otherwise damaged. See the section in this manual on Warranty and Customer Service for repair and replacement information.

Disassembly Precaution

Do not disassemble the IMC Series. See the sections in this manual on Maintaining the IMC Seriest, Trou- bleshooting, and Warranty and Service.

Maintenance/Cleaning Precaution

To reduce risk of electrical shock, disconnect the IMC Series from AC power and batteries before attempting any maintenance or cleaning.

Personal Safety Precautions:

Adhere to the following personal safety precautions when installing or working with an IMC Series :

1. Someone should be within voice range or close enough to come to your aid when you work near a lead acid battery.

2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery.

4. If battery acid contacts skin or clothing, wash them immediately with soap and water. If acid enters the eye, flood the eye with cold, running water for at least ten minutes and get medical attention immediately.

5. Never smoke or allow a spark or flame in the vicinity of the battery or engine.

6. Do not drop a metal tool onto the battery. It may spark or short circuit the battery or other electrical parts that can cause an explosion.

7. Remove all personal metal items such as rings, bracelets, necklaces and watches when working near a lead acid battery. A battery can produce short circuit currents high enough to weld a ring or the like to metal, causing a severe burn.

8. Do not use the IMC Series for charging dry cell batteries that are commonly used with home appliances. These batteries may burst and cause personal injury and property damage.

9. NEVER charge a frozen battery.

Preparing to Charge Precautions

CAUTION

To reduce risk of injury, charge only lead acid, gel, NiCAD or AGM batteries. Other types of batteries may burst, causing personal injury and damage.

PRUDENCE

Pour réduire le risque de blessure, la charge seulement premier acide, le gel, NiCad ou les piles d'AGM. Les autres types de piles peuvent éclater, causant la blessure et les dommages personnels.

Before charging a battery with the IMC Series, read the following precautions:

1. If it becomes necessary to remove the battery from the boat to charge, first remove the grounded terminal from the battery. Make sure all accessories in the vehicle are off, so as not to cause an arc.

LT-IMCHRGR120-1 Issue 1 Print 2

2. Be sure the area around the battery is well ventilated while the battery is being charged. Gas can be forcefully blown away using a piece of cardboard or other non-metallic material as a “hand fan”.

3. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.

4. Add distilled water in each cell until battery acid reaches levels specified by the battery manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps, carefully follow the manufacturer’s recharging instructions.

5. Study all battery manufacturer’s precautions, such as removing or not removing cell caps while charging and recommended rates of charge.

6. Determine the voltage of the battery by referring to the owner’s manual. Make sure that the output voltage selector switch is set at the correct voltage. If the charger has an adjustable charge rate, charge the battery initially at the lowest rate.

Grounding Precautions

IMC Series is intended to be permanently mounted and must have a grounding conductor.

1. The IMC Series should be connected to a metal, grounded, permanent wiring system. An equipment-grounding conductor should be run with the circuit wiring and connected through the IMC Series housing grommets to the equipment grounding (GRN) terminal on the IMC Series.

2. Connections to the IMC Series should comply with all local codes and ordinances.

MOUNTING

The IMC Series™ charger is designed to be wall mounted with vents down on a bulkhead in a protected area away from rain or spray and as close to the batteries as possible.

While the IMC Series™ is designed to maintain a cool touch exterior, sufficient clearance must be allowed for heat dissipation and cooling. It is strongly recommended that the IMC Series™ be mounted is such a way that there is at least 6 inches of free air clearance on the bottom.

Choosing Mounting Hardware

As with any marine equipment, secure mounting is of utmost importance. The bolts or screws used to secure the IMC Series™ charger must be 1/4 inch in diameter, backed with a flat washer, and kept vibration-free with a splitring lock washer. If using bolts, they must be long enough to be secured on both sides of the bulkhead. If using screws, they should be at least 1 inch long. All hardware should be corrosion-resistant.

Mounting the IMC SeriesE Charger

All corrosion-resistant mounting hardware should be readily available. Follow the steps below to mount the IMC Series™ charger to the bulkhead while referring to Figure 1.

Step Action

1. Hold the IMC Series™ charger mounting template vertically flush on the bulkhead.

2. Mark the mounting holes.

3. Remove the IMC Series™ charger mounting template and save.

4. Drill the “A”, “B” and “D” mounting holes.

5. Insert the mounting hardware half-way into the drilled “A” mounting holes.

6. Hang the charger on the “A” keyholes, these holes are only used to expidite mounting, not intended to secure charger to bulkhead.

7. Insert the mounting hardware for the “B” and “D” labeled holes to lock the charger down.

8. Secure all mounting hardware.

LT‐IMCHRGR120‐1Issue 1 Print 2

WARNING

The IMC SeriesE blower exhausts the heat the IMC SeriesE generates during operation through the vent holes on the bottom of the case. In addition, this exhausted air helps cool the case. Blocking the airflow on the bottom of the case will result in charger overheating and shutdown.

AVERTISSEMENT

La soufflerie de Collection d’IMC épuise la chaleur la Collection d’IMC produit pendant l’opération par les trous de conduit dessous du cas. Par ailleurs, ces aides épuisées d’air refroidissent le cas. Bloquer le flux d’air dessous du cas aura pour résultat la surchauffe de chargeur et l’arrêt.

11.25”

16.2”

8”

Figure 1. Mounting Dimensions

WIRING

DANGER

To maintain protection from fire, only use conductors recommended in this manual.

DANGER

Pour maintenir la protection du feu, seulement les conducteurs d'usage ont recommandé dans ce manuel.

Wire Recommendations

The wire gauges in Table 1 are the minimum requirement for making wire connections.

Note: Use only copper or copper-clad wire. Do not use steel or aluminum wire.

LT-IMCHRGR120-1 Issue 1 Print 2

Table 1. Minimum Wire Gauge Requirements

120VAC Input 240VAC Input DC output Model 25’ 50’ 100’ 25’ 50’ 100’ 15’ 25’ 93−IMC80−A 10 AWG 8 AWG 8 AWG 12 AWG 12 AWG 10 AWG 4 AWG 2 AWG 93−IMC100−A 6 AWG 6 AWG 4 AWG 10 AWG 8 AWG 8 AWG 2 AWG 1/0 AWG 93−IMC120−A 4 AWG 4 AWG 4 AWG 8 AWG 6 AWG 6 AWG 1/0 AWG 2/0 AWG

Alarm Contacts should be 26 AWG for all models Proper wire is provided with optional temperature sensor

Connection Points

The wiring is housed in the AC and DC wiring Compartments. Access these compartments by loosening the retained screws as shown and pulling down slightly on the Wiring Compartment Cover. Replace all covers and tighten screws after installation is complete.

Loosen screws to access main AC and DC wiring compartments

Figure 2. Main Wiring Compartment Access

LT‐IMCHRGR120‐1Issue 1 Print 2

For 120VAC operation, connect Neutral/White to L1 and Line/Black to L2

Remote Display Port

Ground Line 1

Line 2

Use only UL listed terminal terminated wires, torque down to 20 in−lbs

Figure 3. AC Cover Removed from IMC

Easy Change Connectors

Alarm Relay Contacts

Smart Memory Button

Remote Temp Sensor Input

Easy Change Connector Set Screws

Bank 1

Frame (Earth) Ground

Bank 2 Bank 3

Bank 4

Figure 4. DC Cover Removed from IMC

Common Return

+ 18 hidden pages

Charles 93-IMC80-A, 93-IMC100-A, 93-IMC120-A Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual