FUM-2410CBP / FUM-2415CBP / FUM-2420CBP 3 stage
Contents
1. Fullwat FUM 2410CBP FUM 2415CBP FUM 2420CBP 3 stage battery charger User s manual TEMP NSOR BATTERY FLOAT SENSO TYPE VOLTAGE MODE CAL CAL WET BATTERY CHARGER AGM POWER SUPPLY GEL REMOTE CONTROL DC OUTPUT AA O Mr lp D W O KOA Ze ae Zr AA a semi Q Eusa D BZ BATTERY 1 Me Tre BD g g S N 8 SY s BULK O D FO 8 CHARGER ON O Q FUSE D ea y SY BATTERY 2 D Keep this manual in a safe place for quick reference at all times This manual contains important safety and operation instructions for correct use of the battery charger Read through the manual and pay special attention to the markings and labels of the charger battery and equipment connected to the battery system Pay special attention to these two types of notices used in this manual WARNING Failure to heed this warning may cause injury to persons and damage to equipment CAUTION Failure to observe this warning may result in damage to equipment and improper functioning of the charger WARNING The charger is designed for in door use Protect the charger from ingress of water This charger is made to charge only properly sized lead acid batteries Charging other types of battery or under sized lead acid batteries may cause fire or explosion Install the charger in accordance with all local codes Do not use the charger if it has been dropped or damaged2. Do not remove casing of the charger there is no user serviceable parts inside Do not charge the battery on boats Remove the battery and charge on shore Never attempt to charge a frozen battery Never attempt to charge a damaged battery Wear protective goggles and turn your face away when connecting or disconnecting the battery Never place the charger on top of a battery Never smoke use an open flame or create sparks near battery or charger during normal charging operation as batteries may giveout explosive gas e Do not charge batteries in an enclosure box in due to possible explosion of entrapped explosive gas e Use of accessory not recommended may cause risk of fire electric shock e Disconnect the mains supply before connecting or disconnecting the links to the battery e Ifthe charger does not work properly or if it has been damaged unplug its AC and DC connection CAUTIONS Refer to battery manufacturer s specific recommended values for battery type settings and float voltage setting Fix the charger to a stable surface using the holes at the flange Ensure all ventilation ports are not obstructed for efficient fan cooling keep loose soft material or paper off at the bottom of the charger If longer output charging cord is required make sure the diameter is adequate for the current in given cable length User s manual l FUM 2410 15 20CBP Fullwat Congratulations on purchasing our new 3 Stage IUoU swi
3. capacities are a generalized suggestion some batteries can take higher charge current check with battery manufacturers for charging batteries with smaller capacity Charger model FUM 2415CBP 15A FUM 2420CBP 20A FUM 2425CBP 25A Battery capacity 50 Ah 150 Ah 70 Ah 200 Ah 80 Ah 250 Ah C _Battery charger installation and connection Observe the warnings amp safety precautions before rushing to install and operate the charger Check battery condition fill up cells for wet battery clean battery poles Secure the battery charger in a well ventilated place make sure the mounting surface is flat and without soft covering material or loose paper sheet The air intake is at the bottom and air outlet at the back Make sure both intake and outlet are not blocked Never place charger on top of battery Plug in the AC mains and turn on power switch the charger ON LED and the float LED should be on green indicating charger is in good order for charging lead acid battery Before connecting or disconnecting the charging cable turn off the power switch and unplug AC cord from the mains First connect the red cable to positive terminal of charger and the battery positive pole Then connect the black cable to the negative terminal and the negative pole of the battery Make sure all the connections are secured and well tighten up double check on the correct polarity Double check again for correct selection
4. unless the battery is fully charged up If the bulk LED is on most of the time then the load is too large G1 As a stand alone power supply It can also be used as a stand alone power supply without connection to a battery It will provide a constant voltage according to the selected float voltage 26 4 27 0 27 6V and rated DC current of the charger However it is not recommended for high surge load such as lamp in stand alone application as the initial high surge current will trigger the overload protection of the power supply Power supply 2 stage charger mode application TEMP REMOTE CONTROL SENSOR BATTERY ae FZ DC OUTPUT CALICAL AA 3 WET BATTERY CHARGER oe i AGM A H POWER SUPPLY Z GEL CHARGE STATUS GY FUSE D DB FAULT oe Float O D DAA ABSORPTION O FUSE D AA BULK O DB 5 CHARGER ON O GY FUSE D H User s manual 5 FUM 2410 15 20CBP H Temperature sensor Warning The temperature sensor must be installed at the negative terminal of the battery terminals wrong connection to the positive terminal will damage the charger and the sensor The temperature sensor is available as an optional accessory ATS 5120 and is used to optimal charging over wide ambient temperature range Fix the temperature sensor optional accessory in a position on the battery which is not affected by other cooling or heating source Plug in the
5. Float voltage selection 26 4 V 27 0V 27 6V In this stage the battery is full and only takes in the amount of current necessary for maintaining the capacity The float voltage is preset independently by user according to the type of battery such that battery can be connected permanently to the charger when it is not in use E Manual equalization charging for wet type battery only Wet lead acid battery requires periodic high voltage charging about 10 overcharge absorption voltage to balance the voltage of each cell reverse the high concentration of electrolyte at the bottom and clear up large sulfate crystals on the plates You can use the Calcium Calcium selection to perform the manual equalization by carefully following the battery maker s recommended frequency and duration Make sure to manually switch off charger when time is up Take special precautions as battery will emit explosive gas during equalization charge F Dual bank charging This feature is for caravans and vehicles with two separate batteries The two batteries must be of same chemical make up and type to avoid over and under charging because only one setting of charging profile for both Two batteries are charged simultaneously and the battery with the lowest level gets most share of the current in the bulk charge stage until it is up to the same voltage level of the second battery battery with higher initial level Both batteries will go to the absorpt
6. ion and the float charge at the same time U ser s manual 4 FUM 2410 15 20CBP Fullwat G _Power supply 2 stage charger mode see Fig At this mode the Charger On 5 LED becomes red color and only bulk and float LED will function The bulk LED will be off when battery is charged to about 80 full The 3 stage charger becomes a 2 stage charger or as power supply in this selected mode because 3 stage charger overcharges battery with external load This selected mode is intended for use to charge battery with external load such as caravan or other battery and external load combination A 2 stage charger can be used as a combination charger power supply An external load can draw current from the charger while the charger is recharging a battery The charger doesn t care how much current is being diverted by an external circuit as it switches from bulk mode constant current to float mode based only on the battery terminal voltage However a 2 stage charger cannot completely charge the battery when the charger switches from bulk mode to float mode After switching to float mode the battery will in most cases be about 80 recharged The battery receives the remaining recharge while in float mode over several days It is highly recommended to switch back to the 3 stage charger mode periodically when the external load is disconnected Also the external load should not be more than 50 of the max current of the charger
7. ion charging with preset constant max voltage FLOAT LED Green 5 FAULT LED Red Float charging with preset constant voltage Charger malfunction See trouble shooting 6 Car blade fuse Thermal fuse for reverse polarity protection 7 Charging banks Screw terminals to connect to supplied charging cable 8 Temperature sensor socket Connection to optional accessory ATS 5120 Sensor to increase decrease charge voltage at low high battery temperature 9 Remote control socket Connection to optional accesory ABD 4120 To remote display the charging voltaje amp charging status and remote control the charger output ON OFF User s manual 2 FUM 2410 15 20CBP Fullwat POWER 10 Power switch To turn on and off AC power to charger 11 Inlet AC socket wirh fuse holder B Battery type selection AGM GEL Sealed type VRLA AGM GEL maintenance free automotive or deep cycle lead acid batteries Wet Flooded type lead acid batteries to which water can be added automotive or deep cycle Calcium Calcium Sealed type VRLA lead acid batteries with calcium content automotive or deep cycle B1 Float voltage selection These fine tuned selections of float voltages enable the best voltage level for maximum battery life Choose 13 8V when in doubt or in power supply mode Follow the markings on deep cycle batteries of the standby float voltage B2 Recommended battery capacity The following minimum Ah
8. lace battery Check charged battery label and change battery type selection to correct setting Total battery capacity is too high for dual charging Check battery capacity or charge battery separately Battery temperature too high Use temperature sensor optional accessory Battery is defective Replace battery A load is connected to battery and charger is not in power supply mode The connected load is too large using most of the current from the charger Wrong battery type selection Change charger selector switch 2 to power supply mode Reduce the load to about 50 of the charger s rating current or take away the load and set charger to battery charger mode to fully charge the battery befote return back to the power supply setting and load connection Check charged battery label and change battery type selection to correct setting Battery is excessively depleted and the soft charging is triggered Recharge the battery after a day if bulk light remains after several hours the battery is most likely damaged and cannot accept charge Replace battery Battery temperature too high Use optional accessory temperature sensor User s manual FUM 2410 15 20CBP Fullwat FUM 2410CBP FUM 2415CBP FUM 2420CBP Absorption charge voltage selections Gel 28 2V AGM 28 6V Wet 28 8V Calcium Calcium 31 1V Absortion charge timer Limited not over 4 hours Floa
9. of slide switch 1 at charger mode switch 2 for battery type and switch 3 for float voltage setting value User s manual 3 FUM 2410 15 20CBP D Fullwat Normal 3 stage IUoU charging operation The 3 stage IUoU charge algorithm ensures fast complete and at the same time gentle charging of the lead acid battery 3 STAGE CHARGING DIAGRAM S 0 C BATTERY S STATE OF CHARGE TIME BULK CHARGE ABSORPTION CHARGE FLOATING CHARGE CONSTANT CURRENT CONSTANT VOLTAGE CONSTANT VOLTAGE Fig 2 Stage 1 THE I PHASE The constant current charging bulk LED is on Normally the battery is charged at constant maximum current until it rises to the selected absorption voltage level The charging voltage changes with the battery voltage If the initial battery voltage is less than 18V due to deep discharge the bulk charge current is reduced to half of the maximum until battery voltage rises over 18V Stage 2 THE Uo PHASE The constant voltage charging absorption LED is on Battery type selection Gel 28 2V AGM 28 6V Wet 28 8V Calcium 31 1V When the battery voltage rises to the selected absorption voltage level the charging switches to constant voltage charging and battery is over 85 full The battery is kept at this high voltage while the current reduces gradually to set value at which the charger automatically switches to float stage Stage 3 THE U PHASE The constant voltage charging float LED is on
10. t charge voltage selections 26 4V 27 0V 27 6V Battery charger power supply selections Yes Maximum output charging current 15A 25A continuous Recommended battery capacity range 50 150 Ah 70 200 Ah 80 250 Ah Soft start bulk charge Battery voltage to trigger cut in soft start lt 18V Output bulk charge mode Soft start bulk charge current current limit Line regulation 90 260V for charging lt 0 5 current ae Ripple and noise peak to peak lt 250mV lt 250mV lt 250mV Efficiency at maximum power 100 230VAC gt 86 90 gt 86 90 gt 86 90 type Input AC voltage range 100 260 VAC 50Hz p AC current at full load 100 230V AC 5 6 2 4A TAIZ 2A 9 3 3 9A 90 110 rated output current or 50 rated output current soft charge Overload ita ates Protection type constant current limiting recovers automatically after fault condition is removed Protection K Specifications 5 stage battery charger power supply mode vs lt Charge phase bulk absortion float eS Indicators Fault mode Ves pe AC power ees Yes Accesories M es EMC EN 55014 Ves Others Dimeisionsand weicht 220 x 80 x 200mm 220 x 80 x 250mm 220 x 80 x 261mm g 2 4Kg 2 8Kg 3 2Kg All values are based on the standard ambient temperature 25 C and pressure 0 1Mpa OR 7673 2200 0012 Rev 3 0 08 2009 TR 24XX CBP BIG Rev 3 0 08 2009 User s manual 8 FUM 2410 15 20CBP
11. tching mode battery charger Introduction This battery charger is suitable for wet sealed RVLA calcium calcium gel and AGM in both car SLD and deep cycle type of lead acid battery It is a set and forget automatic charger which can be permanently connected to battery These models have dual charge banks for charging two batteries simultaneously The special selectable Power Supply mode allows charging battery with external load Intended use All automotive marine mobile home electric scooters golf carts solar deep cycle UPS standby industrial amp comercial applications A Control and indicators TEMP REMOTE CONTROL Q FUSE D BATTERY FLOAT TYPE VOLTAGE MODE CAL CAL wer BATTERY CHARGER AGM POWER SUPPLY CHARGE STATUS FAULT O FLOAT ny waT O E ABSORPTION O BULK O CHARGER ON O FUSE AII JY Fig 1 1 Battery charger power supply selection Slide switch to set charger to 3 stage charger or power supply mode See section G 2 Battery type selection Slide switch to set charger for AGM gel wet and calcium calcium type battery 3 Float voltage selection Slide switch to set float charge voltage to 26 4 27 0V 27 6V 4 Charge status LED display Charger ON LED BULK LED Red ABSORPTION LED Orange Green 3 stage charger mode Red Power supply mode Bulk charging with constant max current Absorpt
12. temperature sensor before switch on the charger to activate the temperature control function never plug in the charger during charging I Cable size selection WAG BATTERy POWER CHARGER SUPPLy Fig 5 Wiese iea Maximum one way Maximum one way Maximum one way AWG mm distancie for 2 voltage loss distancie for 2 voltage loss distancie for 2 voltage loss 24V 15A 24V 20A 24V 25A 10 5 26 4 65 m 15 3 feet 3 50 m 11 5 feet 2 80 m 9 2 feet 8 8 37 7 31 m 24 feet 5 48 m 18 feet 4 39 m 14 4 feet 6 13 3 11 58 m 38 feet 8 84 m 29 feet 7 01 m 23 feet 4 21 2 18 29 m 60 feet 13 71 m 45 feet 10 97 m 36 feet 2 33 6 29 26 m 96 feet 21 94 m 72 feet 17 68 m 58 feet 1 0 53 5 46 94 m 154 feet 35 35 m 116 feet 28 04 m 92 feet 2 0 67 4 58 52 m 192 feet 43 89 m 144 feet 35 05 m 115 feet 4 0 107 85 95 m 282 feet 64 62 m 212 feet 51 51 m 169 feet Table Selection of cable zise and length versus current User s manual FUM 2410 15 20CBP J Trouble shooting PROBLEM INDICATIONS Charger does not work No DC output Battery does not get full charge Long charging time float light does not come on even after 20 hours charging time Bulk LED is on all the time Indicator lights not turn on Charger ON LED is not on float and fault LEDs are ON All indica
13. tor LED work normally and sequentially Absorption light remains on all the time Bulk light remains on all the time when charger is in power supply mode LED 2 is on red Bulk light remains on all the time when charger is in battery charger mode LED 2 is on green Fullwat POSSIBLE CAUSES No AC power SUGGESTED SOLUTION Check AC connections are correct AC input socket fuse blown Output short circuit Replace with correct AC fuse by qualified electrician Check DC connections between charger and battery Over temperature protection triggered Check air intake vent at bottom of charger is blocked or not Check charger ambient ventilation Severe over loading charger Check battery Ah capacity within recommended range Reverse polarity connection Bad battery connection Check for correct polarity replace car blade fuse 7 Check for loose contact right cable size cable integrity Battery type select switch in wrong setting Recheck battery type and change to correct battery selection Battery capacity too large Make sure charger rating matches battery capacity See table B2 Ambient temperature too low Move battery to a room temperature location or get an optional temperatura sensor Battery has damaged cell or battery is too old Wrong battery type selection eg charge gel battery with Calcitum Calcium or wet type selection Rep
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