DLS
SERIES
POWER CONVERTERS & BATTERY CHARGERS FOR 48-VOLTS
OWNER’S MANUAL
Thank you for purchasing IOTA’s DLS Series Power Converter/Battery Charger. When utilized properly, your DLS Power
Converter/Battery Charger will provide years of dependable service. This Owner’s Manual contains important safety and
operating instructions. READ ALL INSTRUCTIONS AND SAFETY PRECAUTIONS CAREFULLY BEFORE INSTALLING
AND OPERATING THE UNIT.
WARNING
Risk of SERIOUS INJURY OR DEATH
This unit is an electrical device. When working with this, or any
electrical device, there exists the potential for
ELECTRICAL SHOCK, EXPLOSION and FIRE hazards.
Before using this equipment, READ AND UNDERSTAND the
instructions, warnings, and safety precautions in this Owner’s
Manual. Failure to read and understand these instructions could
result in SERIOUS INJURY or DEATH.
SAVE THESE INSTRUCTIONS
CAUTION
When working with the DLS unit, always observe the following guidelines:
• The DLS is designed for indoor use. Do not use outdoors.
• DO NOT expose the DLS unit to rain, snow, or other
inclement weather.
• Do not mount the DLS in a zero clearance compartment or
in compartments with flammable items such as gasoline
or batteries.
• Do not mount the DLS in an area with the potential of
dust, debris, or other foreign materials entering the vents
of the DLS.
• Use of an attachment or device with the DLS not recommended by IOTA Engineering will void the warranty and
may result in a risk of fire, electrical shock, or injury to
persons.
• To reduce the risk of damage to the electric plug and cord,
always pull by the plug and not the cord when disconnecting the unit.
• DO NOT operate the DLS with a damaged cord or plug.
• DO NOT operate the DLS if it has been dropped, received
a sharp blow, or has been otherwise damaged in any way.
Take the DLS unit to a qualified service location.
• DO NOT disassemble the DLS unit. Take the DLS to
a qualified service location when service or repair is
required.
• To reduce the risk of electric shock, DISCONNECT the
DLS charger from ALL power sources before attempting any maintenance or cleaning. Turning off any electrical supply or load to the unit is not sufficient and will not
reduce this risk.
• DO NOT use extension cords. Using an improper
extension cord could result in a risk of fire and electric
shock, and may result in property damage, personal
injury or death.
DANGER
ELECTRICAL SHOCK HAZARD
THIS CHARGER IS AN ELECTRICAL
DEVICE THAT CAN SHOCK AND CAUSE
SERIOUS INJURY.
DO NOT CUT POWER CORDS.
DO NOT SUBMERGE IN WATER OR GET
THE CHARGER WET.
EXPLOSION HAZARD
UNSUPERVISED, INCOMPATIBLE, OR
DAMAGED BATTERIES CAN EXPLODE IF
USED WITH A CHARGER.
DO NOT ATTEMPT TO CHARGE DAMAGED
OR FROZEN BATTERIES.
USE THE CHARGER ONLY WITH BATTERIES OF RECOMMENDED VOLTAGE.
OPERATE THE CHARGER IN
WELL-VENTILATED AREAS ONLY.
WARNING
FIRE HAZARD
A CHARGER IS AN ELECTRICAL DEVICE
THAT EMITS HEAT AND CAN BURN.
DO NOT COVER THE CHARGER.
KEEP THE CHARGER AWAY FROM
COMBUSTIBLE MATERIALS.
DO NOT SMOKE OR USE ANY
OTHER SOURCE OF ELECTRICAL
SPARK OR FIRE WHEN OPERATING
THE CHARGER.
RISK OF EXPLOSIVE GASES
WORKING IN THE VICINITY OF LEADACID BATTERIES IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE
GASES DURING NORMAL BATTERY
OPERATION. FOR THIS REASON, IT IS
OF UTMOST IMPORTANCE THAT YOU
FOLLOW THE INSTRUCTIONS WHEN
USING THE BATTERY CHARGER.
To reduce the risk of battery explosion, follow
these instructions and those published by the
battery manufacturer and review all Cautions
and Warnings associated with these products.
PRODUCT DESCRIPTION
INSTALLATION GUIDELINES
IOTA DLS-48-20 Power Converter and DLS-54-13 Battery
Chargers convert 120 volts nominal A.C. to volts D.C. As a
power supply, the DLS-48-20’s tightly controlled regulation
allows the user to operate any 12 volt nominal D.C. load up
to the converter’s rated output current. As a battery charger, the DLS-54-13 will maintain the battery, delivering its
full-rated current when the battery capacity falls sufficiently
low. The voltage is set to deliver its maximum current for
the necessary period of time that minimizes undue stress
to the battery caused by heating of its cells. This helps to
ensure the longest possible life of the battery. Over time,
as the battery nears its full capacity, the converter will floatcharge the battery to prevent self-discharge of its cells.
PROTECTION FEATURES
The IOTA Power Converters/Battery Chargers are designed with high quality components to help ensure
years of continuous use. The unit is protected by multiple
protection features for a long, trouble-free life.
1) Reverse Battery Polarity Protection. 2) Brown-Out In-
put Protection. 3) Over-Current Protection - cycle by cycle
peak limiting as well as rated current limiting to maximize
the life of the converter. 4) Over-Temperature Protection.
In addition, it is designed with a unique “proportional” fan
control circuit. Fan speed is directly proportional to the
converter’s internal ambient temperature. This enables
the fan to turn on and off very slowly, minimizing unwanted
fan-starting noise.
MOUNTING LOCATION
The IOTA Power Converter/Battery Charger can be mounted
in any position within an enclosed or interior compartment.
Provide sufficient air space to allow unrestricted airflow in and
around the unit. Provide at least 4″ around the fan of the DLS
to allow for proper air intake.
DO NOT mount the unit in a zero clearance compartment.
DO NOT mount the DLS in the same compartment with
flammable items such as gasoline or batteries. There are no
components within the DLS unit that, during normal operation,
produce arcs or sparks. However, all electronic devices have
some potential for generating sparks in the event of failure
which can result in explosion or fire.
DO NOT mount the DLS in an area that has the potential of
dust, debris, or other foreign materials to enter in through the
DLS vents.
DO NOT place the DLS directly above the battery; the gases
from the battery can corrode and damage the DLS.
BATTERY CONNECTION
Before you connect the DLS to the battery, make sure that the
AC power cord is NOT plugged into an electrical outlet.
Disconnect the positive side of the battery before installation.
Connect the positive (red) and negative (black) terminal lugs to
battery or load (lugs require a #2 square drive). Always use the
proper size wire based on the amperage of the converter and
the battery. When connecting to a battery, a breaker should be
installed within 18″ of the battery, connecting the battery positive to the line side of the breaker, and the IOTA unit to the load
side. Connect “Chassis Bonding Lug” on the IOTA unit to vehicle
chassis or other grounding source. Refer to Illustration 1.
WARRANTY
The IOTA Power Converters/Battery Chargers are warranted from defects in materials or workmanship for two
years from date of retail purchase, and limits the remedies
to repair or replacement. This warranty is valid only in
the continental United States and Canada. For complete warranty details, contact Customer Service or visit
www.iotaengineering.com.
120 VOLT A.C. INPUT
Plug the unit A.C. input cord into an appropriate 120-volt 3-wire
grounded source. Refer to Illustration 2 for specifications of the
cord provided with your DLS unit. See the Technical Specifications Chart on page 4 for maximum current draw and required
input voltages.
DO NOT USE EXTENSION CORDS - Using an improper
extension cord could result in a risk of fire and electric shock,
and may result in property damage, personal injury or death.
DO NOT OPERATE THE DLS WITH A DAMAGED CORD OR
PLUG. Have the cord or plug replaced immediately by qualified
service personnel.
REVERSE POLARITY FUSES
The IOTA Battery Charger/Power Supply is protected against
reverse polarity on the DC output. If a battery or the unit is
hooked up incorrectly, the fuses will blow and can be easily
replaced. Always use the same size and style fuse that came
with the converter. To change the fuses, use a screwdriver
to loosen the screws and remove the fuses. Always replace
the fuses with the same type and rating. After inserting the
new fuses, tighten the screws firmly. Apply 5 inch-pound
maximum torque. DO NOT OVERTIGHTEN. Note: some
DLS models require only one fuse. For these units, a small
fiberglass spacer may be used in the empty fuse slot to aid
with tightening.
ILLUSTRATION 1 - DLS CONNECTIONS*
DLS SERIES M
DLS-54-13
ILLUSTRATION 2 - AC INPUT PLUG
DLS-54-13
NEMA 5-15P PLUG
FOR 15A RECEPTACLE
DLS-48-20
DLS-75
CHARGE CONTROL FOR THE DLS-54-13
TWO-STEP VOLTAGE JACK
The two-step voltage jack of the DLS-54-13 allows switching
from a long-term float voltage of 54.4vdc to a ‘high-stage’
voltage of 56.8vdc. When the included dual voltage plug is inserted in the jack*, the voltage rises to 56.8vdc for occasional
fast charging. When the plug is removed, the voltage drops to
54.4vdc to reduce battery water loss. WARNING: To avoid
battery damage, remove the Dual Voltage Plug when
quick-charging is complete. NOTE: If the unit is equipped
with an internal IQ4 smart charger, two-step charging is not
needed and the Dual Voltage Jack is disabled.
ILLUSTRATION 3 - DUAL VOLTAGE JACK
DLS-48-20
*Actual component locations may vary depending on model.
NEMA 5-20P PLUG
FOR 20A RECEPTACLE
THE IQ4 LED INDICATOR
(ONLY ON IOTA MODELS WITH INTERNAL IQ4)
IOTA Models with an internal IQ4 smart-charger give the
user the benefit of automatic Bulk, Absorption, and Float
stage charging. This increases the charging capacity of
the IOTA charger, decreases charge times and insures
proper and safe battery charging without over-charging.
The green LED on the fan end of the unit will indicate which
charging phase the IOTA unit is currently in. When the unit
is first activated, the LED will flash as it reads the number
of cells in the battery. The unit will then proceed directly
to the Bulk charging or Float charging phase depending
on the charge status of the battery. Use the LED CODE
TABLE for reference when checking the LED. Units that do
not have an internal IQ4 smart-charger can easily install
an external IQ4** that plugs into the available Dual Voltage
Jack. Contact Customer Service for more information.
**Use only the IQ4-54V model smart charge controller for 54V DLS units.
Location of the Dual Voltage Jack may vary depending on model.
TECHNICAL SPECIFICATIONS CHART
RATINGS AND SPECIFICATIONS
DC Output Voltage (No Load) approx.
Output Voltage Tolerance (No Load)
Output Amperage, Max Continuous
Output Voltage (Full Load) approx.
Maximum Power Output, Continuous
Ripple and Noise
Input Voltage Range
Input Voltage Frequency
Maximum AC Current (@108Vac)
Typical Efficiency
Max Inrush Current, Single Cycle
Short Circuit Protection
Overload Protection
Line Regulation
Load Regulation
Fan Control
Thermal Protection
Working Temperature Range
Storage Temperature
Withstand Voltage (VDC)
**
Approximate Dimensions
Weight
48V (DC)
+ or - .5%
20Amps
>47.8V (DC)
950 Watts
<100 mV rms
108 - 132 AC
47-63
17.1 Amps
>80%
40 Amps
Ye s
>100%
100 mV rms
<1%
PROPORTIONAL
YES
0° - 40° C
-20° to 80° C
1700/1700/500
13″ x 6.5″ x 3.4″
7.8 lbs
**
Primary to Chassis/Primary to Secondary/Secondary to Chassis*Unit is not UL Listed
DLS-54-13*DLS-48-20*
SERIES M
54.4V (DC)
+ or - .5%
13 Amps
>54V (DC)
700 Watts
<100 mV rms
108 - 132 AC
47-63
12.6 Amps
>80%
30 Amps
Ye s
>100%
100 mV rms
<1%
PROPORTIONAL
YES
0° - 40° C
-20° to 80° C
1700/1700/500
9.7″ x 6.7″ x 3.4″
5.0 lbs
Distributed By:
IOTA ENGINEERING PO BOX 11846 TUCSON, AZ 85734 TEL: 1-800-866-IOTA (4682) FAX: (520) 741-2837 WEB: www.iotaengineering.com
68357-036 REV 1409
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