Merlin PowerGuard PRO Installation Manual
PowerGuard
PRO
User & Installation Guide Rev A Page 1
PowerGuard
PRO
Flat Battery Protection System
User & Installation Guide
Revision A
Merlin Equipment Ltd
Clyst Court
Hill Barton Industrial Estate
Exeter, Devon, EX5 1SA
United Kingdom
T: +44 (0) 1202 697979
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
PowerGuard
PRO
User & Installation Guide Rev A Page 2
WARNING
Your attention is drawn to “Caution!” and “Warning!” statements throughout this manual.
“Caution!” refers to practices that may cause damage to the PowerGuard
PRO
or your electrical
system.
“Warning!” identifies practices that may cause injury or death.
PowerGuard
PRO
is designed for installation by qualified and
competent electrical engineers.
Qualified and competent engineers will be familiar with safe working
practices, local health & safety legislation and the proper and safe use of tools
and equipment. 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 PowerGuard
PRO
, contact
your Dealer or Merlin Power Systems for advice.
PowerGuard
PRO
User & Installation Guide Rev A Page 3
Precautions
• This product is designed for use in 12Volt DC and 24Volt DC
vehicular systems depending on model. Use in other than its
designed application may result in fire, electric shock or other
injury.
• DO NOT disassemble, modify or alter. Doing so may result in an
accident, fire or electric shock.
• USE ONLY in vehicles with a NEGATIVE GROUND. Failure to do
so may result in fire, electric shock, damage or other injury.
• FUSES: Use the correct ampere rating when replacing fuses.
Failure to do so may result in fire, injury, electric shock or
damage.
• DO NOT install or operate the CPU in an explosive atmosphere.
• DO NOT install or expose the CPU to excessive temperatures or
humidity.
• If in any doubt consult a suitably qualified and competent
engineer or the supplier.
• DO NOT substitute Contactors or switches with any other types
that have not been approved and tested.
• 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.
PowerGuard
PRO
User & Installation Guide Rev A Page 4
Certificate of Conformity
Declaration of Conformity
Merlin Equipment Limited, Trading as Merlin Power Systems hereby declares that the product
marketed as PowerGuard
PRO
is in compliance with the requirements of EU Electromagnetic
Compatibility (EMC) Directive 2014/30/EU.
PowerGuard
PRO
complies with RoHS (Reduction of Hazardous Substances) Directive 2011/65/EC.
At the end of life, PowerGuard Pro should be disposed of as normal electrical waste.
PowerGuard
PRO
has been tested to and surpasses ISO-7637-2 for use on vehicles.
Signed:
James Hortop
Managing Director
Merlin Power Systems UK
Date: 18th January 2019
VCA Approval Number: 10R-059235
Test report: TRA-025368-38-00A
PowerGuard
PRO
User & Installation Guide Rev A Page 5
Introduction
Thank you for purchasing a PowerGuard
PRO
.
PowerGuard
PRO
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.
PowerGuard
PRO
is also a Flat Battery Protection System. Using sophisticated battery monitoring
techniques, PowerGuard
PRO
detects when batteries start to run low. When the batteries have run
below a certain level for a pre-set period of time, the battery will be disconnected. Note: on the
primary battery circuit, this is inhibited from happening when the engine ignition is switched on.
PowerGuard
PRO
may be used on 1 or 2 battery bank installations at either 12 or 24VDC. Those
battery banks may also be of mixed voltage (e.g. a 12 and a 24V battery bank).
Please take the time to read and understand this manual before installation and use.
Please note that this manual refers to the PowerGuard
PRO
retail product. PowerGuard
PRO
is available
in an OEM version. The OEM version differs slightly to the retail product. However, the main printed
circuit board within PowerGuard
PRO
is identical so this manual may also be used for setting up the
OEM version.
Contents
Precautions ............................................................................................................................................. 3
Certificate of Conformity ........................................................................................................................ 4
Introduction ............................................................................................................................................ 5
Contents .................................................................................................................................................. 5
Package Contents .................................................................................................................................... 6
Installation .............................................................................................................................................. 7
Positioning of Parts ............................................................................................................................. 7
Wiring Layouts .................................................................................................................................... 8
Contactor Rating ................................................................................................................................. 9
Installation and Set Up .......................................................................................................................... 10
Location and Connections ..................................................................................................................... 11
Settings.................................................................................................................................................. 13
Notes ................................................................................................................................................. 14
After Installation - Testing .................................................................................................................... 15
Product Specifications........................................................................................................................... 16
Warranty ............................................................................................................................................... 17
PowerGuard
PRO
User & Installation Guide Rev A Page 6
Package Contents
Single Battery
Models: 04-8101(12V) and 04-8102(24V)
• PowerGuard
PRO
CPU x1
• PowerGuard
PRO
Contactor x1. Part Number: SU80-5164MPL(12V) or Part Number SU80-5165(24V)
• Remote Battery Isolator Switch x1
• Flat Battery Protection Reset Switch x1
• Fuse Kit & Rubber Blanking Plugs
• Installation Manual (this document)
Twin Battery
Models: 04-8103(12V) and 04-8104(24V)
• PowerGuard
PRO
CPU x1
• PowerGuard
PRO
Contactor x2. Part Numbers: SU80-5164MPL(12V) or Part Numbers SU80-5165(24V)
• Remote Battery Isolator Switch x2
• Flat Battery Protection Reset Switch x1
• Fuse Kit & Rubber Blanking Plugs
• Installation Manual (this document)
PowerGuard
PRO
CPU Contactor Switch
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