PFC-50
PFC-50B
PFC-75
Charger
Owner’s Manual
Rev 0.1
©2008 Manzanita Micro
The information date is: 06/10/2008
PFC-50 BATTERY
CHARGER MANUAL
rev 0.1
General Overview
The Manzanita Micro PFC-50 series is a unique line of powerful, efficient battery
chargers. The chargers will run off of any voltage from 100 up to 240 AC These
chargers can be set to run automatically when plugged in yet they also have far
more user adjustable functions than other electric vehicle chargers. Every model is
user adjustable to charge batteries from 12 to 450 Volts. All the chargers are power
factor corrected and are available with enhanced options. With so much flexibility
and power output up to 75amps your PFC charger may be the last charger you ever
need to buy.
Speed and Efficiency
The essential ingredient for fast recharge times is to deliver high power to the
battery. The key to polite opportunity charging is to be able to share outlets with
other equipment and make efficient use of limited current. The PFC-50 line of
chargers have an adjustable throttle knob to allow the chargers to be turned down to
operate on very limited power sources. Efficiency and power factor are both better
than 0.9.
What does the PFC mean?
In the Manzanita Micro chargers PFC stands for Power Factor Corrected. This
means that current and voltage are drawn in unity, (ie: current is drawn with unity to
the incoming line voltage).
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Dimensions and Model Ratings
The PFC-50 series chargers weigh in at approximately 42 pounds and reside in a
box that is 19.5 x 10.5 x 6.5 inches.
The 50 in PFC-50 is indicative of the number of amps that the charger is rated to
draw from the AC line. Unlike some other chargers this is the rated continuous load
and all the chargers are thoroughly tested to their rated limits before leaving
Manzanita Micro.
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Charger Operation
figure 02: PFC-50 Layout
Turning the Charger On and Off
There is an ON/OFF Breaker to the left of the blue user control panel at the top of
the charger. This breaker is the main switch to turn the charger on or off. If ever
there is a concern while charging first shut off this breaker switch.
NOTICE! DO NOT unplug the blue SB-175 Anderson connectors (DC line) from
your charger while it is charging! If the battery pack is disconnected while the
charger is putting out power the charger can be damaged. Failure to heed these
warnings may result in significant internal damage to the charger which is not
covered under your warranty!
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User Control Panel
The user interface panel is the long blue panel with yellow text near the top of the
charger. The only thing most users need be concerned with are the LED indicators,
the VOLTS TRIM and the adjustable AMPS knob. Below are explanations of each
feature in order from left to right. Refer to figure 02 for specific locations.
“VOLTS TRIM”
This controls the peak DC voltage ceiling that the charger will allow the batteries to
reach before limiting the current. Unless specified otherwise, the voltage limit is
specifically calibrated and set by Manzanita Micro to 191 Volts (for a 156V nominal
pack.) In the event that adjustment is desired, please follow the instructions below.
NOTICE! Always use an appropriately sized insulated screw driver when adjusting
the voltage trim potentiometer. Suitable drivers are available for purchase from
Manzanita Micro or other electronics components manufacturers. (Mouser part #:
594-8T000, Vishay/Spectrol Adjust Tool, www.mouser.com)
figure 03: Adjustment Tool # 008T000
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VOLTS TRIM CALIBRATION:
Try to make sure your battery pack is fully charged before adjusting (or else you will
have to continually monitor it and make more adjustments).
1. Turn the amps knob all the way down (full counterclockwise).
2. Make sure the charger is plugged into the battery pack and that there are no open breakers or
open fuses in the DC battery circuit.
3. With the charger’s AC breaker switch in the OFF position, plug the charger into the AC power
outlet.
4. Now turn ON the charger’s AC breaker switch. The fans should come on.
5. Using an appropriate insulated screw driver, stick it into the VOLTS TRIM access hole and turn
the internal adjustment potentiometer until you find the threshold where the yellow LIMITS LED
changes state. If the yellow LED is off, turn the trim pot counterclockwise to get it to go on. If the
yellow LED is on, turn the trim pot clockwise to get it to go off. Once you find the threshold where
the LED changes states, the cutoff voltage is set to the actual battery voltage and the charger will
not charge the pack above this voltage. Therefore, when you are ready to charge you will need to
turn the trim pot clockwise to raise this voltage ceiling. Then turn the AMPS knob up until you can
put the amount of amps you want into the battery pack while not letting the batteries go over their
peak voltage limit according to their manufacturer’s data.
While charging, when the battery pack voltage hits the peak limit the yellow LIMITS
LED will come on along with the flashing blue TIMER LED.
figure 03: VOLTS TRIM Adjustment
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“REG BUSS”
This is the 6 pin RJ jack where the BMS communication line plugs into the charger.
This port allows the individual battery regulators to communicate with the charger.
NOTICE! If your vehicle is equipped with a Battery Management System, Ensure
that the reg buss data cable is fully plugged into the charger whenever the vehicle is
charging. The communication data cables are hooked to the regulators in a daisy
chain fashion. Make sure that each of the smaller data cables are all plugged in
where they should be before charging. If there is an unplugged portion of the reg
buss, the charger cannot communicate with the regs and this could lead to
potentially damaging situation if there is an un-matched battery cell in the
pack! The RJ connectors are similar to phone cord connectors and they are
designed to snap into place and stay connected. If a cable is disconnected insure
that it is fully reconnected. An audible *click* should be heard when the RJ plug is
fully inserted and it should not be able to be pulled out without first pinching the
small plastic tab underneath the plug.
“POWER” - Green LED
The bright green POWER LED indicates when the charger is on. Input power
coming in and the main breaker is in the ON position.
“WARN” - Red LED
The red WARN LED should blink briefly when the charger is first powered up and
then remain off for the duration of the charge. If ever this indicator is on, turn down
the AMPS knob immediately, turn off the charger’s breaker switch and consult
Manzanita Micro or a qualified service technician. This LED could indicate an over
voltage or over temperature condition. It could also be indicative of an open in the
pack. Turn down the AMPS knob and check to make sure there is no open in the
battery pack circuit. Check the blue SB-75 Anderson connector to insure that it is
connected and look for other disconnected battery cables. If the charger will not
work, contact the vendor you bought the charger from or Manzanita Micro.
NOTICE! DO NOT let the charger try to put current into the battery pack if there is
an open in the circuit. Never unplug the blue SB-75 Anderson connectors (DC line)
from your charger while it is charging! If the battery pack is disconnected while the
charger is putting out power the charger can be damaged. Failure to heed these
warnings may result in significant internal damage to the charger which is not
covered under your warranty!
“AMPS” Knob
The AMPS knob allows the user to adjust how much current the charger will move.
If the vehicle is always plugged in to the same circuit this shouldn’t need any
adjusting but if the user were to have it set at 50 amps and then plug into a 15 amp
110V outlet it will quickly open a circuit breaker or fuse on the AC line. The vehicle
operator may wish to adjust this knob when plugged in to a public outlet especially if
there is no easy access to the electrical panel for that circuit. Additionally, the user
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might need to turn down the charger if there are other loads on the branch circuit
(example: A stereo and a computer are running on the same 15 amp circuit).
“LIMITS” - Yellow LED
The yellow LIMITS LED indicates that the charger has reached its peak voltage limit.
This should happen only at the end of the charge cycle when all the batteries are
fully charged. The LIMITS indicator should be accompanied by the blinking blue
TIMER LED which indicates that the charger is in current cutback mode and the
timer is counting down to the end of charge.
If the yellow LIMITS LED is blinking, then it is indicating that there is an over
temperature condition and the charger is in thermal cutback mode.
NOTE: When using regulators, the blue TIMER LED will often come on before the
LIMITS LED because the battery regulators let the charger know when the batteries
are getting full before the voltage limit is reached. If the LIMITS light is coming on
frequently or before most of the regs are blinking, this could be indicative of a few
batteries whose voltages are getting too high. It could also mean that someone has
improperly adjusted the VOLTS TRIM. Consult your Battery Regulator user’s
manual or recalibrate the VOLTS TRIM setting on the charger.
“TIMER” - Blue LED
The blue TIMER LED indicates that the charge is complete or near completion. If it
is flashing it means that charging is almost finished and the charger is backing off
the current and counting down the timeout timer. When the blue LED is steady, it
means that the timeout timer has ended and the charger has finished charging the
pack. At this point the charger should be putting out no power and drawing less than
an amp off the input line.
“TIMER ADJ”
This stands for timer adjustment. This is a small 16 position rotary switch which
allows the user to adjust the amount of time that the charger stays in contant voltage
mode, while cutting back current at the end of a charge cycle before it shuts of
completely.
If the timer is ever to be changed, adjustments are as follows. If the switch is at ‘0’
then the timer will time out instantly - do not use this setting. (‘0’ is the 3-o-clock
position when viewed from the front). If the switch is at ‘1’ it will go for 15 minutes
before completely cutting back power. Each additional tick after ‘1’ adds 10 more
minutes to the charge cutback time. Turning the switch clockwise all the way around
to the 2:30 position will give the maximum amount of time (about 255 minutes)
before timeout.
To reset the timer, turn off the power to the charger and then turn it on again.
“SWITCHES”
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The red and white dip switch module is on the upper right end of the charger. This is
a bank of 8 switches and they are numbered starting with #1 on the far right.
NOTICE! Adjusting these switches can cause the charger to perform in an
undesirable manner. Please be sure you understand these switch features before
changing them.
Dip Switch Guide:
1. Engages timer at peak voltage limit set point. This switch should be ON
2. Starts timer as soon as the charger is turned on. This can be used for timed
charging. This switch should be OFF
3. Starts timer when the reg buss commands. This switch should be ON
4. Reg buss latch disable. As soon as a reg trips it will start the timer and the
charger will back down until timeout. This should be ON
5. Low battery detection on specially equipped chargers. This switch should be
OFF
6. AGM battery equalization. When using Mk2 series battery regulators, this will
allow the batteries to climb to a slightly higher voltage for equalization
at the end of charge. It also commands the yellow LEDs on each reg
to turn on. This switch should be OFF
7. As soon as the high voltage limit is set the charger goes off. This should be
OFF
8. Auto restart function. This allows the charger to restart charging when the
battery pack reaches a certain set low voltage point. This switch should be
OFF unless using the auto restart feature.
NOTE: Dip switch #6 can be useful if you have battery regulators because you can
momentarily switch it on and the yellow lights on all the regs should come on. If any
don’t, you can use this feature to narrow down which reg(s) are not communicating
with the charger. This feature does not work with the new LT-5 Lithium regulators.
For more information visit: www.manzanitamicro.com
Or for technical questions or other inquiries:
Manzanita Micro
Rich Rudman
PO Box 1774
Kingston, WA 98346
Phone: 360-297-1660
Cell: 360-620-6266
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