Marinco - Actuant Electrical 16202, 16061, 16102, 16153 Owners Manual

Intelligent Charging System Series

OWNER’S MANUAL

ON BOARD BATTERY CHARGERS

Models Amperage No. Of Banks Volts 16061 16102 16153 16202

6 Amps 1 Bank 12 6,6 Amps 2 Banks 12 or 24 6,6,6 Amps 3 Banks 12 or 24 or 36 10,10 Amps 2 Banks 12 or 24

IMPORTANT NOTICE

This manual contains important safety and operating instructions for the charger. Read the entire manual before using. Also read all instructions and cautions for and on the charger, batteries and equipment in the vicinity of the batteries.

SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety and operating instructions for the charger. Read the entire manual before using. Also read all instructions and cautions for the charger, batteries and equipment in the vicinity of the batteries.

WARNINGS

THIS CHARGER SHOULD BE USED TO CHARGE ONLY FLOODED LEAD ACID, AGM OR GEL CELL TYPE BATTERIES. USE ON OTHER BATTERY TYPES MAY CAUSE THE BATTERY TO EXPLODE AND CAUSE PERSONAL INJURY.

RISK OF EXPLOSIVE GASES! WORKING IN THE VICINITY OF LEAD ACID BATTERIES IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. THEREFORE IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER YOU FOLLOW THE INSTRUCTIONS EXACTLY.

AC Connection and Grounding Precautions

DANGER

DO NOT OPERATE THIS CHARGER WITH A TWO BLADED ADAPTER PLUG OR EXTENSION CORD. DOING SO CAN RESULT IN SERIOUS PERSONAL INJURY.

AFTER SECURING THE BATTERY CONNECTIONS, PLUG THE AC LINE CORD INTO AN AVAILABLE AC OUTLET THAT IS PROTECTED BY A GROUND FAULT CIRCUIT INTERRUPTER (GFCI) BREAKER.

CAUTION

TO REDUCE THE RISK OF SHOCK, CONNECT ONLY TO A PROPERLY GROUNDED OUTLET

NOTE: AC Line Cord color-coding is EU style. Line = Brown, Neutral = Blue, Ground = Green

Table of Contents

IMPORTANT SAFETY INSTRUCTIONS 2

INTRODUCING THE CHARGER 4

Personal Safety Precautions 4 Preparing to Charge Precautions 5

INSTALLING THE CHARGER 5 – 18

Choosing a Mounting Location 5 Mounting The Charger 6 Making DC Connections 6 Setting Up The Battery Chemistry 6 Making AC Connection 7 DC Output Wiring Configurations 7 - 18

Page

OPERATION OF THE CHARGER 19 - 20

LED Function Chart 19 Charger Algorithm Chart 20 Battery Fault Indication 20

TROUBLESHOOTING 21 – 22

MAINTAINING THE CHARGER 22

SPECIFICATIONS 23

ADDITIONAL FEATURES 24

EMC NOTICE 24 LIMITED WARRANTY 25

INTRODUCING THE CHARGER

The Guest models 16061, 16102, 16153, 16202 are microprocessor controlled, 3-stage electronic switching battery chargers. Each output produces 12 Volts DC at either a full 6 Amps or 10 Amps (model specific), while using much less AC current than other chargers. Pre-wired on the AC input and DC outputs, these units feature a push button interface that allows the user to configure individual outputs for different battery chemistry types. One tri-color LED per output will indicate which battery chemistry type has been selected. Tri-color LED readout indicates state of charge for each bank. Unlike automotive “trickle” chargers, the 16061, 16102, 16153, 16202 will not boil off the electrolytes in properly installed and maintained batteries. When the charger is connected to your batteries and plugged into a standard 115 Volt / 60 Hz AC outlet, the tri-color LED (red, blue, green) mounted on the face of the charger will let you know the unit is recharging and maintaining your batteries. This sophisticated device is ideal for recharging and maintaining the 12VDC batteries in your boat, electric vehicle, ATV, snowmobile and motorcycle.

Personal Safety Precautions

Adhere to the following personal safety precautions when installing or working with the chargers:

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

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

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

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.

Never smoke or allow an open flame in the vicinity of the battery.

Do not drop a metal tool onto the battery. It may short-circuit the battery, spark and may cause an explosion.

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.

battery manufacturer, if applicable. Do not overfill. Check water levels frequently.

Preparing to Charge Precautions

Before charging a battery with the charger, read the following precautions:

Do NOT operate the charger if the cable or an LED indicator is damaged.

Make sure all accessories on the product you are charging are OFF.

If the battery or batteries must be removed from the product, always remove the grounded terminal from the battery first.

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 nonmetallic material as a “hand fan”.

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

Add distilled water in each cell until battery acid reaches levels specified by the

For a battery without cell caps, carefully follow the manufacturer’s recharging instructions.

Never allow the charger battery connection ring terminals to touch each other.

NEVER charge a frozen battery.

INSTALLING THE CHARGER

Note: The initial installation consists of (a) Choosing a mounting location, (b) mounting

the charger, (c) making the DC connections, (d) selecting the appropriate battery chemistry, (e) making the AC connections to a receptacle that is protected by a GFCI breaker.

Choosing a Mounting Location

The charger should have at least eight inches of unobstructed area on all sides of the unit for effective cooling. The case of this charger may become warm during operation. For optimum performance, mount the charger in the vertical position (cables on the bottom), this will improve the convection cooling (airflow over the back of the charger). Mounting on its side or on a horizontal surface may cause the charger to slightly reduce amperage output due to the thermal protection built in. Do not install the charger on carpeted, upholstered, or varnished surfaces.

Mounting the Charger

For 16061 use corrosion resistant #10 bolts, backed by a flat washer, and secured to the mounting surface with a split-ring lock washer. For the 16102, 16153 and 16202 use corrosion resistant ¼” bolts, backed by a flat washer, and secured to the mounting surface with a split-ring lock washer.

Hold the charger to the mounting surface and mark the holes.

Remove the charger and drill the mounting holes.

Align the charger and assemble the mounting hardware. Secure.

Making the DC Connections

Check polarity of the battery posts. The POSITIVE (POS., P, +) battery post usually has a larger diameter than the NEGATIVE (NEG., N, -) post. Connect Red charger output wire to POSITIVE post, Black charger wire to NEGATIVE. See below diagrams for more details.

Setting Up the Battery Chemistry

Note: The battery chemistry needs to be set for each individual battery bank or charger

output.

The battery chemistry indicators are defined as follows: Flooded Lead Acid (FLA) and AGM Battery Mode Red LED Safe Mode Blue LED Gel Battery Mode Green LED

After you connect the DC cables of the charger to the batteries, the battery chemistry selection LED will illuminate (Safe Mode). At this point, you can toggle thru the different battery chemistry selections by pressing the pushbutton on the membrane panel for each specific output. Once AC is plugged in, this setting will be set by the micro into RAM and it will remember this setting until you interrupt both the battery power and AC power to the charger.

The battery chemistry selection LED will turn OFF 10 minutes after the batteries are first connected; this is called “sleep mode”. To recover from “sleep mode” press the battery chemistry selection button, this will turn ON the battery chemistry selection LED as long as AC power has not yet been applied.

The battery chemistry select LED will turn ON once AC has been applied to the charger and turn OFF 10 minutes after AC has been disconnected.

If you do not know what type of battery you have, please choose the safe mode algorithm, which was developed for an unknown battery chemistry or application requirement.

Making AC Connection

Output 1

After setting your battery chemistry selections for each output, connect the AC plug into an AC receptacle, which is protected by a Ground Fault Circuit Interrupter (GFCI) breaker.

DC Output Wiring Configurations

This section shows possible DC wiring configurations for the following charger models: 16061, 16102, 16153, and 16202.

Diagram 1 – 16061 in a single Independent Output configuration

6 Amp

Diagram 2 – 16102 in a dual Independent Output configuration

Output 1

Start or

Trolling

Output 2

SAFE MO DE

Model12 Amp

16102(6/6)

6 Amp

Engine

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