Redarc BMS1230S2, MANAGER30 User Manual

Battery Management System

BMS1230S2

THE

MANAGER

WARNINGS & SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - This manual contains IMPORTANT SAFETY INSTRUCTIONS for The

Manager30 battery management system.

DO NOT OPERATE THE BATTERY CHARGER UNLESS YOU HAVE READ AND UNDERSTOOD THIS MANUAL

AND THE CHARGER IS INSTALLED AS PER THESE INSTALLATION INSTRUCTIONS. REDARC RECOMMENDS
THAT THE CHARGER BE INSTALLED BY A SUITABLY QUALIFIED PERSON.

RISK OF EXPLOSIVE GASES:
WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE

GASES DURING NORMAL OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU
FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER.

1. The Battery Charger should not be used by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge, unless they are supervised or have been instructed
on how to use the appliance by a person responsible for their safety. Children should be supervised to ensure
that they do not play with the Battery Charger.

2. Do NOT alter or disassemble the Battery Charger under any circumstances. All services or repairs must be
returned to REDARC for repair. Incorrect handling or reassembly may result in a risk of electric shock or fi re and
may void the unit warranty.

3. Use of an attachment not recommended or sold by REDARC may result in a risk of fi re, electric shock, or injury
to persons.

4. The AC power connection must be connected to an earthed socket outlet. Do not use the AC input if the cord is
damaged. Use of a non-genuine or damaged AC input cord may result in a risk of fi re, electric shock, or injury
to persons. (If the supply cord is damaged, it must be replaced by a special cord or assembly available from the
manufacturer or service agent).

5. Cable and fuse sizes are specifi ed by various codes and standards which depend on the type of vehicle the
Battery Charger is installed into. Selecting the wrong cable or fuse size could result in harm to the installer
or user and/or damage to the Battery Charger or other equipment installed in the system. The installer is
responsible for ensuring that the correct cable and fuse sizes are used when installing this Battery Charger.

6. When charging a battery, make sure the settings at the Battery Setup menu on the Remote Monitor are correct
for the type of battery under charge. Charging a battery with the wrong profi le may cause the Battery Charger
to indicate a fault or give misleading results and cause injury to persons, damage to the Battery Charger and/or
property. Noticeable oscillations between Boost and Absorption stages indicate the wrong choice of battery type.
Check and adjust battery type. If you are unsure of the battery type or settings to use, set to the Gel setting.

7. Only use the Battery Charger for charging Standard Automotive Lead Acid, Calcium Content, Gel, AGM, SLI,
Deep Cycle or Lithium Iron Phosphate type 12V batteries.

THE MANAGER30

The Manager30 Battery Management System is a complete charging solution for your
Lead Acid or LiFePO

4

Auxiliary or House battery. The system incorporates 12V Solar, 240V
AC and 12/24V DC inputs to provide a 12V charging output at a maximum 30A rating.
The system also includes a Remote Monitor which provides information such as current,
voltage and temperature as well as a simplifi ed battery percentage and charge rate.

1

SAL.FOR.Instruction Manual.BMS1230S2 – Version 3

2

WARNINGS & SAFETY INSTRUCTIONS

8. When using the Battery Charger to charge a Lithium Iron Phosphate battery, only batteries that feature an inbuilt

battery management system featuring inbuilt under and over voltage protection and cell balancing are suitable.

9. NEVER smoke or allow a spark or fl ame in vicinity of battery. This may cause the battery to explode.

10. Be extra cautious so as to reduce the risk of dropping a metal tool onto a vehicle battery. Doing so might cause

the battery to spark or might short-circuit the battery or other electrical parts that may cause an explosion.

11. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid

battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal,
causing a severe burn.

12. A SPARK NEAR A BATTERY MAY CAUSE THE BATTERY TO EXPLODE. TO REDUCE THE RISK OF A SPARK

NEAR A BATTERY WHEN CONNECTING THE BATTERY INSTALLED IN A VEHICLE TO THE BATTERY CHARGER,
ALWAYS DO THE FOLLOWING:

Always wire the Output Connector before connecting it to the Battery Charger. During connection of the unit,

the Battery Output (positive) must be connected fi rst, followed by the Ground (chassis) terminal. The chassis
connection should be made away from the battery and fuel lines. DC Input (positive) should be connected
last. Once all connections are wired to the Output Connector, plug the connector into the Main Unit.

When disconnecting the Battery Charger, remove the AC Connector fi rst, followed by the CAN connection then

the Output Connector from the Main Unit. The DC Input should be disconnected next, followed by the Ground
(chassis) connection, then the Battery Output connection if complete removal is necessary.

13. PERSONAL SAFETY PRECAUTIONS
To assist with the safe operation and use of the Battery Charger:
a) Consider having someone close by to come to your aid when you are using the Battery Charger.
b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
c) Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery.
d) If battery acid contacts your skin or clothing, remove the affected clothing and wash the affected area of your

skin immediately with soap and water. If battery acid enters your eye, immediately fl ood the eye with running
cold water for at least 10 minutes and seek medical assistance immediately.

e) To improve user safety it is recommended to control the charger and monitor the charging process using the

remote away from the vicinity of the battery being charged.

1. Do NOT connect computers or IT equipment to the Charger front panel connector or remote. Damage may occur.

2. It is recommended to leave the remote connected at all times to the base unit.

3. The Main Unit must be fi xed using suitable screw mounts. Failure to adequately mount the unit, such as using

adhesives to mount the unit will result in unreliable operation of the charger.

4. When using the charger in Storage mode, make sure that all loads are disconnected from the house battery

under charge. Failure to do so may cause the house battery to be under charged, give false readings on the
State of Charge indicator and possibly cause damage to any loads connected.

5. A partially shaded panel (or low-light conditions such as dawn or dusk) will increase the target solar panel

voltage level to match the maximum power point. In this situation solar will be selected as a source however
little or no current will be fl owing into the battery.

6. Modifi cation of the ‘Advanced Settings’ menu items affect the way the Battery Charger responds to charging situations.

Modifi cation of these settings may result in the Battery Charger not functioning at 100% of its capacity. These settings
should only be modifi ed if absolutely necessary and when the effects of the changes are 100% understood.

7. Touring mode will achieve it’s best charge level if a Storage mode charge has been recently performed.

8. It is the installers responsibility to ensure their installation complies with any applicable legal and regulatory

requirements. Within Australia, installers may wish to consult AS/NZS 3001 as one potentially relevant standard.

3

CONTENTS

Table of Contents Page

Warnings and Safety Instructions 01
Contents 03
Features and Benefi ts 04

1 Introduction 05

1. General Description 05

2. The Remote Monitor 05

3. The Kit Includes 05

4. Specifi cations 06

5. Multi-stage Charging Process 08

6. Maximum Charging Current Setting 10

7. Green Power Priority 10

2 INSTALLATION Guide 11

1. System Layout 11

2. Mounting Instructions 11

1. Mounting the Main Unit 12

2. Mounting the Remote Monitor 13

3. Mounting the Battery Sensor 16

3. DC Cable Size Requirements 16

4. The Manager30 Wiring Connections 18

1. Load Disconnect Feature 18

2. Ignition Trigger Feature 18

3. Connecting the Battery Sensor 19

4. Wiring the Main Unit 19

5. Batteries 21

6. MPPT Solar Regulator 22

3 USER Guide 23

1. Remote Monitor 23

2. Understanding the Display 23

3. Initial Setup 24

4. User Menu 25

5. Settings Menu 27

6. Fault Screens 31

7. Troubleshooting 32

8. Factory Settings 34

9. FAQs 35

4 Remote Drill Template 36
5 Two Year Warranty 38

4

FEATURES AND BENEFITS

1. The Manager30 incorporates six products in one, it’s a DC-DC charger, a 240-volt

charger, a solar charger, a dual battery isolator, a load disconnect controller and a
remote battery monitor. The Manager30 will automatically select between charging
sources, requiring no input from the operator during its operation.

2. The Manager30 has no fan, which makes it SUPER quiet and very reliable.

3. The Manager30 is designed and manufactured in Australia, for Australian conditions,

using the latest electronic and design technologies. It is manufactured with high­quality components to ISO9001 quality and ISO14001 environmental standards and
backed with REDARC’s quality service and two-year warranty.

4. The Manager30 charging algorithm uses solar whenever possible making the unit

more energy effi cient and better for the environment.

5. The Manager30’s DC-DC charging enables optimal charging of house batteries, even

if they have different chemical characteristics from the vehicle battery. The input
voltage can be above, equal to or below the output voltage.

6. State of Charge (SOC) indication means you will always know how fully charged the

battery is and how much longer it will need to achieve full charge. An easy to operate,
high-quality, user friendly graphical display module lets you know what’s going on at
all times.

7. The Manager30 is very reliable and includes reverse polarity protection (without

depending on fuses) and short circuit protection. The unit has undergone stringent
safety & electrical compliance testing.

8. The Manager30’s easily selectable charging profi les make it suitable for charging all

lead-acid battery types and suitably protected LiFePO

4

battery types commonly used

in modern caravans and motorhomes.

9. The Manager30 disconnects automatically from the vehicle battery, so there is always

power to start the car.

10. Sophisticated fault detection monitors the house battery condition during all stages

of charging, keeping you and your caravan/ camper/ RV safe.

11. The Manager30 has a separate battery sensor to monitor battery conditions and

state of charge even while The Manager30 is in standby mode. The battery sensor
monitors current, voltage and temperature of the house batteries.

12. Automatic temperature and voltage drop compensation.

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1 INTRODUCTION

1.1 General Description

The Manager30 is designed to offer a complete solution to battery charging and
maintenance needs for recreational automotive applications.

The Manager30 incorporates AC, DC and Solar inputs to achieve the best charge
to a house battery.

1.2 The Remote Monitor

The Manager30 comes with a Remote Monitor designed to give you house
battery information and charge status along with critical system information
while charging is in progress.

With the Remote Monitor, you can customise how your house battery is charged
and monitor where the charge is coming from, keeping you in control at all times.

The Remote Monitor can be surface mounted on a wall, or recessed (into the
dashboard of an RV for example).

1.3 The Kit Includes

Main Unit

Battery Sensor

Remote Monitor

Output Connector

T-Piece (RJ45 with RJ12 insert)

CANBus Cables (1m & 5m)

Power Cable

1

2

3

4

5

6

7

2009/19/EC adapting to Council Directive 72/245/EEC relating to radio interference
(electromagnetic Compatibility) of vehicles, clauses 6.5, 6.6, 6.8 & 6.9 only.
2004/104/EC: 14th October 2004 adapting to technical progress of Council Directive
72/245/EEC relating to radio interference (electromagnetic compatibility) of vehicles.

IEC 60335-2-29:2002 (Fourth edition) + A1:2004 in conjunction with
IEC 60335-1:2001 (Fourth edition) +A1:2004 +A2:2006
EN 60335-2-29:2004 in conjunction with
EN 60335-1:2002+A1+A2+A11+A12+A13

RoHS

Compliant

6

1 INTRODUCTION

1.4 Specifi cations

Electrical Specifi cations
Inputs
AC Input

Input Voltage Range (nominal) 220-240VAC 50Hz
Power Rating 520W
Effi ciency 80% - 90%
Connection IEC Mains Plug

DC Input

Input Voltage Range 9 - 32V
Turn ON/OFF Threshold 12V (24V) 13.2V/12.7V (26.4V/25.4V)
Power Rating 520W
Effi ciency 94%
Connection Phoenix 1967498 Connector

Solar Input

Input Voltage Range 9 - 32V
Turn ON (Open Circuit Voltage) 17.5V
Power Rating 520W
Effi ciency 93%
Connection Phoenix 1967498 Connector

Max Volts @ Battery Terminals (25°C Nominal)

Storage Mode Touring Mode Float

Gel Setting 14.4V 14.4V 13.5V
AGM Setting 14.4V 14.4V 13.5V
Calcium Setting 16.0V 15.2V 13.5V
Standard Lead Acid Setting 15.5V 14.8V 13.5V
Lithium Setting 14.5V 14.5V 13.6V
Output Current (Nominal) 30A

Temperature Compensation

Standard Lead Acid, AGM, Gel or Calcium Battery +30mV / °C < 25°C < -30mV / °C
Lithium Setting 40°C < 0.5%/°C < 60°C
Operating Temperature* -40°C - 80°C
Over Temperature Shutdown Yes
Total Battery Capacity 40 - 800Ah
Output Battery Volts (Nominal) 12V
Output Battery Volts (Minimum) 4V
Maximum Current on Load Disconnect Wire 1A
Memory Save on Battery Disconnect Yes

Output Protection

Short Circuit Protection Yes
Surge Protection Yes
Reverse Polarity Protection Yes
Overload Protection Yes

Compliance

CE 2009/19/EC

2009/104/EC
Safety IEC60335
Environmental RoHS Compliant

General Specifi cations

Main Unit Dimensions 445x185x79mm
Remote Dimensions 186x74x29mm
Kit Weight 5.5kg
Warranty 2 years

* The Manager30 will only charge the battery when the battery temperature is between 0°C and 60°C in order
to protect the battery from damage.

7

1 INTRODUCTION

27

74

186

21 29

185

429

445
404

82

79

Figure 1.4.1 - Main Unit Dimensions

Figure 1.4.2 - Remote Monitor Dimensions

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1 INTRODUCTION

1.5 Multi-stage Charging Process

The Manager30 incorporates two different multi-stage charging profi les – Touring
(3-stage) and Storage (8-stage) – which can be selected in the Battery Mode
menu on the Remote Monitor.

Touring Mode

Touring mode is designed for use when ‘on the road’. Touring mode offers a
3-stage charging profi le consisting of Boost, Absorption and Float stages (see
Figure1.4.1). In Touring mode, the house battery is monitored to detect only a
limited number of faults such as short circuit, over current and over voltage. This
allows The Manager30 to operate correctly even when loads are connected to the
house battery. This mode will always produce an output (unless a fault condition
is detected) and will cycle through the three stages as required to maintain the
house battery as outlined in Figure 1.4.1.

Touring mode will achieve its best charge level if a Storage mode charge has been
recently performed.

BOOST

ABSORPTION

FLOAT

FloatAbsorptionBoost

Voltage

SLA & Lithium

Current

Touring Mode Charging Process

Figure 1.4.1 - Touring Mode Charging Process

9

1 INTRODUCTION

Storage Mode

Storage mode is designed to charge the house battery to its optimal level and
maintain that level while your caravan is in storage. This mode requires all loads
to be switched off or disconnected from the house battery before charging. It
uses a 8-stage* charging profi le consisting of Desulphation*, Soft Start, Boost,
Absorption, Battery Test, Equalise*, Float and Maintenance stages (see Figure1.4.2).
Storage mode is designed to detect a wide range of battery fault conditions, for
more information on these fault conditions, please refer to the Troubleshooting
section of this manual. Unlike Touring mode, Storage mode does not cycle. This
means that when the charging process is completed, The Manager30 will always
remain in either Float or Maintenance stages. Float stage will provide the house
battery with a ‘trickle’ charge whenever the house battery voltage drops below a
predetermined threshold to ensure the battery stays charged. Maintenance stage
turns The Manager30 output off, but continues to monitor the house battery and
will revert to Float stage when necessary.

NOTE: If The Manager30 is set to Storage mode and the vehicle is started
The Manager30 will automatically switch to Touring mode once it senses an
increase in input voltage from the alternator.

When using the charger in Storage mode, make sure that all loads are disconnected from
the house battery under charge. Failure to do so may cause the house battery to be under
charged, give false readings on the State of Charge indicator and possibly cause damage
to any loads connected.

*The Lithium profi le does NOT incorporate a Desulphation stage.
**The Lithium, AGM and Gel profi les do NOT incorporate an Equalise stage

BATTERY TEST

FLOAT

SOFT START

DESULPHATION

Desulphation*

Current

Storage Mode Charging Process

BOOST

ABSORPTION

MAINTENANCE

EQUALISE

MaintenanceFloatEqualise**AbsorptionBoostSoft Start Batt. Test

Voltage SLA

Voltage Lithium

Figure 1.4.2 - Storage Mode Charging Process

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1 INTRODUCTION

IMPORTANT

When The Manager30 is set to ‘Storage’ mode and no valid charging sources are
connected, it will enter a ‘Sleep’ mode 30 seconds after the last user interaction.
The sleep mode is designed to limit the amount of current drawn from the output
battery by the system whilst in Storage mode and does this by switching the
screen and all non-essential functions off. The Manager30 will ‘wake-up’ from
its Sleep mode if a button is pushed or if any valid input source is sensed, though
this may take 30-60 seconds to occur after the source is connected.

1.6 Maximum Charge Current Setting

The Manager30 allows the user to set the maximum charge current for their
battery, making it suitable for charging batteries as small as 40Ah in capacity.
When the charge current is set below the maximum 30Amps, the current supplied
to charge the battery is restricted to the user setting. Any excess current is used
to power loads running from the battery under charge.
If no loads are running from the battery, total current from The Manager30 will be
restricted to the level set by the user.

1.7 Green Power Priority

The Manager30 is designed to charge from multiple sources simultaneously
to charge the auxiliary/house battery. If the Solar power input is available the
maximum available solar power will be used before topping up the output
charging current from another source if available (e.g. mains). Priority is given to
Solar then to AC Mains power, then to DC Vehicle power.

11

2 INSTALLATION GUIDE

2.1 System Layout

2.2 Mounting Instructions

This section describes how to mount the three major components of The
Manager30: the Main Unit, the Remote Monitor and the Battery Sensor.

Vehicle
Battery

(Not Supplied)

House Battery

(Not Supplied)

BMS1230

Solar Panels

(Not Supplied)

Remote
Monitor

To Loads

(Not Supplied)

Battery
Sensor

240VAC

Mains Power

DC - DC

Power Source

Figure 2.1.1 - System Layout

Figure 2.2.1 - The Manager30 System