MFJ MFJ-4416C Instructions
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MFJ-4416C Super Battery Booster Instruction and Technical Manual
Contents
INTRODUCTION & FEATURES ........................................................................................................3
INTRODUCTION .............................................................................................................................3
FEATURES .......................................................................................................................................3
Adjustable Output Voltage:...........................................................................................................3
Selectable Minimum Input Voltage:..............................................................................................3
Audio Alert Feature:......................................................................................................................3
External Boost Enable:..................................................................................................................4
Remote Jack:..................................................................................................................................4
TYPICAL SPECIFICATIONS.......................................................................................................... 4
EASY START INSTRUCTIONS.......................................................................................................... 4
SYSTEM CONTROLS AND INDICATORS ....................................................................................... 5
Top Inputs and Outputs: ....................................................................................................................5
Side A Controls and Indicators:......................................................................................................... 6
Side B Controls and Indicators:.........................................................................................................6
CONNECTION AND OPERATION ....................................................................................................7
DC Power Connection: ...................................................................................................................... 7
Remote and External Control Connections: ......................................................................................7
External Control: ...........................................................................................................................7
Remote Control: ............................................................................................................................8
Operation: ..........................................................................................................................................9
INTERNAL HEADER AND CONTROL.........................................................................................9
HDR1 Low Voltage Lockout: .......................................................................................................9
HDR2 Low Voltage Lockout Enable: ...........................................................................................9
HDR3 Audio Alert Enable: .........................................................................................................10
HDR4 Low Voltage Boost Trigger Level: ..................................................................................10
HDR5 Low Voltage Boost Trigger Enable: ................................................................................10
R8 Voltage Adjust: ...................................................................................................................... 10
R41 Enable Time Delay: .............................................................................................................10
F1 Fuse: .......................................................................................................................................10
THEORY OF OPERATION................................................................................................................ 10
Input Filtering:.............................................................................................................................11
SMPS controller: .........................................................................................................................11
MOSFET drivers and transformer:..............................................................................................11
Output Filtering: ..........................................................................................................................11
Over-voltage Protection:..............................................................................................................11
Enable Circuitry:..........................................................................................................................11
External Keying Inputs:...............................................................................................................12
Low Battery Voltage Enable: ......................................................................................................12
Low Voltage Lockout:.................................................................................................................12
Remote Control Input:.................................................................................................................12
IN CASE OF DIFFICULTY................................................................................................................ 13
Low Voltage Disconnect trips under high demand conditions....................................................13
Enable LED fails to illuminate. ................................................................................................... 13
Minimum Battery Voltage........................................................................................................... 13
TECHNICAL ASSISTANCE.......................................................................................................... 13
Schematics ...........................................................................................................................................14
FULL 12-MONTH WARRANTY.......................................................................................................16
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MFJ-4416C Super Battery Booster Instruction and Technical Manual
Figures
Figure 1 Top View ........................................................................................................................ 5
Figure 2 Side A View .................................................................................................................. 6
Figure 3 Side B View................................................................................................................... 6
Figure 4 DC Wiring ..................................................................................................................... 7
Figure 5 External Enable to Amp Key......................................................................................... 8
Figure 6 Remote Control ............................................................................................................. 8
Figure 7 Ignition Sense ................................................................................................................ 8
Figure 8 Internal Jumpers and Controls....................................................................................... 9
Figure 9 Block Diagram............................................................................................................. 10
Figure 10 SMPS Section Schematic .......................................................................................... 14
Figure 11 Control Section Schematic ........................................................................................ 15
INTRODUCTION & FEATURES
INTRODUCTION
The MFJ-4416C Super Battery Booster is designed with the serious mobile operator in mind. In
the mobile environment low battery voltage can cause output signal distortion, output power
problems and even transceiver resetting. This low voltage occurs in two ways. First – even low
resistance wiring can result in noticeable voltage drop. And second when you turn off your
vehicle or remove a typical battery from the charger, the battery voltage can drop from the
nominal 13.8 volts to 12 volts after a short period of time. With this in mind the MFJ-4416C
Super Battery Booster corrects all of these problems. With its high efficiency boost regulator
circuitry, it will maintain the desired 13.8 volts at up to 25 amps ICAS from voltages as low as 9
volts.
The MFJ-4416C has been redesigned to make the device more robust with heavy duty transistors
and rectifiers, improved switch mode transformer, and larger heatsinks on vital components. The
EMI filters on the input and output of the MFJ-4416C are designed to reduce noise to a
minimum so radio reception while on is normally no problem.
FEATURES
Choice of Input and Output Connections: No need to fumble around looking for connectors. The
MFJ-4416C gives you a choice of Anderson PowerPoleTM connectors or 5-way binding posts on
the input and output.
Adjustable Output Voltage: User adjustable output voltage. Factory set at 13.8 volts this
voltage is adjustable anywhere from 12 to 13.8 volts.
Selectable Minimum Input Voltage: You have the choice of the minimum input voltage the
MFJ-4416C will operate on. Set from the factory at 10 volts you can select 9 or 11 volts. This
keeps you from possibly over discharging your battery and damaging it. It is even latchable so
once the voltage drops the Boost Regulator stop until you remove the power from the unit.
Audio Alert Feature: When enable instantly alerts you when the input voltage drops below the
preset level.
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MFJ-4416C Super Battery Booster Instruction and Technical Manual
External Boost Enable: A DE-9 input port with 4 inputs that are used to externally enable the
MFJ-4416C. Two inputs when grounded enable the unit and two inputs when taken high (1012V) will enable the unit.
Remote Jack: Allows sampling of the Input Voltage and the Output Voltage. Also allows for
control of the Boost Switch and has an active low output for the Low voltage alarm. Direct
connection to the MFJ-4416RC Remote Unit.
RUGGED CONSTRUCTION - Attractive all-metal cabinet and conservative component
selections ensure solid performance for years to come. Fully covered by MFJ’s “No Matter
What” one year limited warranty.
TYPICAL SPECIFICATIONS
Output Current……………………..……25 Amps ICAS 30A peak.
Output Voltage …………………………13.8 Volts at 9-13.8 volts input.
Before attempting to operate your MFJ-4416C, please read the manual thoroughly. It contains
important details about setting up your unit to obtain the best performance.
EASY START INSTRUCTIONS
1. Prepare input and the output cables for the MFJ-4416C. It is recommended to use #12 or
larger wire for both the input and output cables. MFJ has cables available for the output
side for use with most HF and VHF/UHF radios.
2. Prior to connecting the radio and battery, plug the input and the output cables in to the
MFJ-4416C and ensure the polarity is correct.
3. Plug the output of the MFJ-4416C into your radio and then attach the input to your
battery.
4. You are now ready to operate. If not using external switching, depress the enable switch.
NOTE: The MFJ-4416C is not designed to boost the voltage of a 6V electrical
system up to 13V and will not run on a positive ground system. It will also not
reduce the voltage of a 24V or higher system to 13V.
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MFJ-4416C Super Battery Booster Instruction and Technical Manual
SYSTEM CONTROLS AND INDICATORS
Top Inputs and Outputs:
1 5
2 6
3 7
4 8
Figure 1 Top View
1. 5-Way High Power Binding Post Negative Input.
2. Anderson PowerPole
TM
Negative Input.
3. Anderson PowerPoleTM Positive Input.
4. 5-Way High Power Binding Post Positive Input.
5. 5-Way High Power Binding Post Positive Output.
6. Anderson PowerPoleTM Positive Output.
7. Anderson PowerPoleTM Negative Output.
8. 5-Way High Power Binding Post Negative Output.
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