WhisperPower Supreme 12 VDC – 60 A User Manual

User Manual
Battery Charger
Enjoy Green Energy
Supreme
Marine | Mobile | Land | 12 V | 20 - 40 - 60 A | 3-step
whisperpower.com
2 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
WhisperPower Battery Charger
12 V 20 - 40 - 60 A 3
For safe and optimum performance, the WP Battery Charger Supreme must be used properly.
Carefully read and follow all instructions and guidelines in this manual and give special attention to
the CAUTION and WARNING statements.
PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE
Disclaimer
While every precaution has been taken to ensure the accuracy of the contents of this guide,
Whisper Power BV assumes no responsibility for errors or omissions. Note as well that
specifications and product functionality may change without notice.
Important
Please be sure to read and save the entire manual before using your WP Battery Charger
Supreme. Misuse may result in damage to the unit and/or cause harm or serious injury. Read
manual in its entirety before using the unit and save manual for future reference.
Product Number:
Article Nr. 61112302
Article Nr. 61112304
Article Nr. 61112306
12V 20A (WP-BC 12/20-3)
12V 40A (WP-BC 12/40-3)
12V 60A (WP-BC 12/60-3)
5001-21062023
Service Contact Information
Email: [email protected]
Phone : +31 (0) 512 571 555
Web : www.whisperpower.com
4 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
TABLE OF CONTENTS
1.
INTRODUCTION5
2.
PRODUCT DESCRIPTION6
3.
UNDERSTANDING THE UNIT
6
4.
INSTALLING THE CHARGER
11
5.
UNIT OPERATION14
6.
SPECIFICATIONS21
7.
WARRANTY23
8.
Appendix24
Appendix A1
Appendix A2
Appendix B
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12 V 20 - 40 - 60 A 5
1. INTRODUCTION
Thank you for purchasing the WP Battery Charger Supreme. With our state of the art, easy
to use design, this product will offer you reliable service by providing a multi-stage multibank battery charger to charge different types of batteries you have installed in your boat,
RV, vehicle or your cabin battery bank.
An innovative feature we offer is the ability to charge your main battery bank as first priority
so that you may charge this main bank quickly. Another unique feature is our silent mode
setting that reduces the charging current at night, thereby reducing the fan noise.
This manual will explain how to use this unit safely and effectively. Please read and follow
these instructions and precautions carefully.
IMPORTANT SAFETY INFORMATION
This section contains important safety information for the WP Battery Charger Supreme.
Each time, before using the unit, READ ALL instructions and cautionary markings on or
provided with the unit, and all appropriate sections of this guide.
The WP Battery Charger Supreme contains no user-serviceable parts. See Warranty
section for how to handle product issues.
WARNING: FIRE AND/OR CHEMICAL BURN HAZARD
Do not cover or obstruct any air vent openings and/or install in a zero-clearance
compartment.
WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH OR
SERIOUS INJURY. KEEP AWAY FROM CHILDREN!
• When working with electrical equipment or lead acid batteries, have someone nearby in
case of an emergency.
• Study and follow all the battery manufacturer’s specific precautions when installing, using
and servicing the battery connected to the charger.
• Wear eye protection and gloves.
• Avoid touching your eyes while using this unit.
• Keep fresh water and soap on hand in the event battery acid comes in contact with eyes.
If this occurs, cleanse right away with soap and water for a minimum of 15 minutes and
seek medical attention.
• Batteries produce explosive gases. DO NOT smoke or have an open spark or fire near
the system.
• Keep unit away from moist or damp areas. Never expose unit to snow, water etc.
• Avoid dropping any metal tool or object on the battery. Doing so could create a spark or short
circuit which goes through the battery or another electrical tool that may create an explosion.
WARNING: Explosion hazard!
• DO NOT use the unit in the vicinity of flammable fumes or gases (such as propane tanks
or large engines).
• AVOID covering the ventilation openings. Always operate unit in an open area.
CAUTION:
• For indoor use only.
• Before charging, read the instructions.
6 WhisperPower Battery Charger
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12 V 20 - 40 - 60 A
his appliance is not intended for use by persons (including children) with reduced
T
physical, sensory or mental capabilities, or lack of experience and knowledge, unless they
have been given supervision or instruction concerning use of the appliance by a person
responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Do not charge non-rechargeable batteries because of the danger of eruption.
During charging, batteries be placed in the ventilated area.
The battery terminal not connected to the chassis has to be connected first.
The other connection is to be made to the chassis, remote from the battery and fuel line.
The battery charger is then to be connected to the supply mains.
After charging, disconnect the battery charger from the supply mains. Then remove the
chassis connection and then the battery connection.
Only allow children at least 8 years old to use the battery charger. Give sufficient instruction
so that the child is able to use the battery charger in a safe way and explain that it is not a
toy and must not be played with. Ensure a child does not try to charge non-rechargeable
batteries because of the danger of eruption.
Examine the battery charger regularly for damage, especially the cord, plug and enclosure.
If the battery charger is damaged, it must not be used until it has been repaired.
FCC/ EMC INFORMATION
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to part 15 of the FCC and to CE directive Rules. These limits are
designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generate, uses and can radiate radio frequency energy and, if
not installed and used in accordance with the instructions, may cause harmful interference
to radio communications. However, there is no guarantee that interference will not occur
in a particular installation. If this equipment does cause harmful interference to radio
or television reception, which can be determined by turning the equipment off and on,
the user is encouraged to try to correct the interference by one or more of the following
measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
• Consult the dealer or an experienced radio/TV technician for help.
LIMITATIONS ON USE
Do not use in connection with life support systems or other medical equipment or devices.
2. PRODUCT DESCRIPTION
The Battery Charger Supreme includes:
- Base unit:
• 61112302 12V 20A (WP-BC 12/20-3) or
• 61112304 12V 40A (WP-BC 12/40-3) or
• 61112306 12V 60A (WP-BC 12/60-3)
- Owner’s manual
- Battery Temperature Sensor 1,5 m
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12 V 20 - 40 - 60 A 7
3. UNDERSTANDING THE UNIT
The Battery Charger Supreme is a fully automatic multistage battery charger with the ability to
charge 3 separate battery banks. When first connected to an AC power source, the charger will
check all three battery banks before charging commences. The charger operates on an isolated
charging design where Battery Bank 1 is separate from Battery Bank 2 and 3. Battery Bank 1
is the priority battery bank in the charging sequence and is recommended to be connected to
the main (or primary house) battery bank. Battery Bank 1 can be programmed with a different
charge algorithm from Banks 2 and 3.
The battery Banks 2 and 3 are connected in parallel internally (with a separation diode) and
share a common charge algorithm.
During normal operation, the charger will do a full charge cycle up to the float stage on Battery
Bank 1 with battery type set to either GEL, AGM, Flooded, Lithium (see Lithium section for
limitations of use). Once the float stage is reached, the charger starts charging both Battery
Banks 2 and 3 with a bulk / absorption mode (Battery Banks 2 and 3 can also be set to either
GEL, AGM, Flooded). On completion, all the three battery banks move to float stage with a
shared battery voltage determined by Battery Bank 1 settings. This setting allows the charger to
remain permanently connected to mains if required. See more details in Appendix B.
Important Note: The battery Bank 1 on the charger should only be connected to the main
battery bank for first priority charging. Battery Banks 2 and 3 on the charger should be
connected to the other battery banks with lower priority (such as jump-start battery bank and/
or AC generator battery bank used in a marine application). On single bank installations, it is
recommended to only use Bank 1 on the charger.
Silent Mode (uses ‘Auto’ icon as indicator)
A unique feature of the WP Battery Charger Supreme is the ability to reduce fan speed at night
or whenever required. This setting is manually activated via the Digital Display. Please note that
charger output current will be reduced (de-rated) to about half while in Silent Mode, leading to
longer recharge times. Please see “Understanding the Auto Mode Function” for more details.
Multi-Stage Charging Process:
The charger is a fully automatic “set-and-forget” design. It is designed to quickly and accurately
recharge deep cycle batteries utilizing charger algorithms that help to maximize the life of
specialized deep cycle batteries.
The charger features a multistage smart charging technology that enables the charger to be
connected to the battery banks permanently.
As dictated by battery manufacturer’s recommendations, deep cycle batteries require a multistage charge sequence for perfect, fast and accurate charging. This charger delivers four
primary charge stages (Bulk Charge, Absorption Charge, Float, and Maintenance).
Bulk Charge ‘bUL’: The battery is charged at a full rated output current of the charger until the
battery reaches the charging voltage, known as its absorption voltage. In this
step, around 80% of the battery is recovered as fast as possible.
Absorption Charge ‘AbS’: With the charger voltage held steady, the remaining 20% is replaced
with the charger allowing the current to drop as the battery approaches its
full charge.
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12 V 20 - 40 - 60 A
Float Stage ‘FLO’: Finally, in the float stage, the charger voltage is lowered and held at a
constant and safe predetermined level. This prevents the battery from being
overcharged, yet allows the charger to supply enough current to make up for
the self-discharge losses of the battery while supporting any additional loads
connected to the battery (such as DC lighting and refrigerators). This stage
allows the charger to be used as a DC power supply.
Maintenance: This is a regular timed recharge (or return to the bulk stage). The charger switches from float stage to bulk charge after 7 days of constant operation to
ensure the battery banks remain active.
AC Wiring
Compartment
DC Output fuses
AC Input Wire
Strain Relief
Remote Control Port
Battery Temperature
Sensor Port
UNIT GND
Battery Pos: (Bank 1)
Battery Pos (Bank 2)
Battery Neg (Common)
Battery Pos (Bank 3)
Typical wiring block diagram of the Battery Charger with 3 batteries bank:
Battery Pos: Bank 1
AC Source:
(90-250VAC,
50Hz/60Hz)
Branch
Breaker
Charger
Battery Pos: Bank 2
Battery Pos: Bank 3
Battery Neg: Common
12V Battery Bank 1
Main Battery
12V Battery Bank 2
Jump Start Battery
12V Battery Bank 3
Generator Battery
Battery Bank 1, 2 and 3:
-B
ank 1 is separate from Bank 2 & 3 and will be charged separately during bulk and absorption
stages.
-B
ank 2 & 3 are charged together and are connected in parallel internally (with a separation
diode). Only one setting is required for Bank 2 & 3.
-O
nce all three battery banks have reached float stage, all three battery banks are connected in
parallel internally (with a separation diode) to maintain the float stage on all the battery banks.
- The charger can charge Bank 1 with the choice of four different battery types (GEL, AGM,
Flooded and Lithium) and charge Bank 2 & 3 together with the choice of three different battery
types (GEL, AGM and Flooded).
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12 V 20 - 40 - 60 A 9
- The charger will charge Bank 1 to float stage first before it charges Banks 2 & 3 (see more
on Section 5 ‘Understanding the Charging Mechanism’). Bank 1 on the charger is highly
recommended to be connected to the main battery bank for first priority charging and Banks 2
& 3 on the charger to be connected to the other battery banks with lower priority (such as jumpstart battery bank and/or AC generator battery bank used in marine application).
- There are two main settings required on the charger for battery charging:
CH 1 setting (Bank 1):
-B
attery type (GEL, AGM, Flooded, Lithium)
-M
aximum charging current (‘h-current’ in A)
- Absorption to float stage current (‘L-current’ in A - GEL, AGM, Flooded battery type only)
-N
umber of charging stages (Mode 2 - Bulk and Absorption stage only, Mode 3 - Bulk,
Absorption and Float stage)
- Battery temperature (Low- ‘Lo’, Normal - ‘nor’, High - ‘hi’)
- Charge voltage (14.2, 14.3, 14.4 in V - Lithium battery type only)
- Charge termination current (‘L-current’ in A - Lithium battery type only)
CH 2 & 3 setting (Bank 2 & 3):
- Battery type (GEL, AGM, Flooded only, No Lithium battery)
- Maximum charging current (‘h-current’ in A)
- Absorption to float stage current (‘L-current in A - GEL, AGM, Flooded battery type only)
- The charger can also be set to power supply mode (Program setting on CH 1). With this
setting, the charger will only provide constant voltage and current to CH 1 only, CH 2 & 3
(Bank 2 & 3) are disabled. No DC voltage or current will be supplied to CH 2 & 3 even if
battery banks are connected to the two channels. The charger will act as a constant voltage
power supply with user selected supply voltage and maximum current.
Branch Breaker:
For AC Input hardwire charging systems, it is required to use a 15A branch breaker to connect
between the AC source and the charger AC input.
AC Source:
The charger accepts full universal input voltage (90 .. 250Vac, 47 .. 60Hz).
Remote Charger Control Port:
Use for external display
The interface port is used for connecting an optional external display. The external display (sold
separately) has identical functions to the built-in display.
BTS Port (Battery Temperature Sensor Port):
CAUTION: RISK OF BATTERY DAMAGE. If the temperature sensor is not being used,
never set the battery temperature lower than the actual temperature. This may overcharge
and damage the battery.
• A WhisperPower Temperature Sensor (sold separately) is available and is used to attach to
one of the batteries. It measures the battery temperature and will make small adjustments
to the battery charging voltage for better battery charging performance. As Bank 1 is
designed for charging the main battery bank on the system, it is highly recommended to
have the battery temperature sensor attached to Bank 1 battery bank.
• If the temperature sensor is not used, you can also manually set the charger to Low - ‘Lo’,
Normal - ‘nor’, or High - ‘hi’ to reflect the environmental temperature for better charging
effect. Manufacturing default setting is set to ‘Normal’ temperature. See more details on
Understanding the Battery Temperature Function in Section 5.
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12 V 20 - 40 - 60 A
Digital Display:
• ‘CH1’, ‘CH2’ and ‘CH3’ represent Battery Bank 1, 2 and 3
respectively. With ‘CH1’ turned on, the numerical value on
the display shows individual battery information like battery
voltage in ‘V’ or charging current in ‘A’. ‘CH 2’ and ‘CH 3’ will
always turn on together, the numerical value on the display
shows the total charging current in ‘A’
• ‘GEL’, ‘AGM’, ‘Flooded’, ‘Lithium’ and ‘Program’ represent
different battery types setting.
• ‘Auto’ indicates Silent Mode is activated
• ‘Mode’ only turns on during the setting of charging stage
Mode 2 - (2 stages: Bulk and Absorption stage)
Mode 3 - (3 stages: Bulk, Absorption and Float stage)
‘Temp’ only turns on when manually setting of battery temperature.
Battery Charger Voltage:
Voltage default settings
Battery Type
Absorption
Float
Equalization
GEL
14.2 V
13.8 V
N.A.
AGM
14.3 V
13.4 V
N.A.
Flooded
14.4 V
13.5 V
16.0 V (See Note 1)
Lithium
Constant 13.9 – 14.4 V (0.1V Step, See Note 2)
N.A
Program
Constant 13.3 – 13.7 V (0.2V Step; See Note 3)
N.A
Note 1: Equalization setting can only be used on flooded battery type selection only.
See more details on the Procedure to Equalize the Flooded Battery section
Note 2: Charger will terminate charging when charging current drops below the set termination value.
Note 3: Charger is acting as a power supply with selected constant output voltage and preset maximum
output current.
Battery Bank Size Recommendation:
The battery charging current rating is based on the battery size. Each battery bank should meet
the minimum Ah rating as shown. If a smaller size battery bank is used, set the current rating to
lower value to match with the battery bank size. Normally, the minimum battery bank capacity is
based on twice the charger current rating.
WP-BC 12/20
WP-BC 12/40
WP-BC 12/60
Current Setting Battery Capacity Current Setting Battery Capacity Current Setting Battery Capacity
5A
Min 10Ah
5A
Min 10Ah
5A
Min 10Ah
10A
Min 20Ah
10A
Min 20Ah
20A
Min 40Ah
15A
Min 30Ah
20A
Min 40Ah
40A
Min 80Ah
20A
Min 40Ah
40A
Min 80Ah
60A
Min 120Ah
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4. INSTALLING THE CHARGER
WARNING: W
hisper Power BV recommends all wiring to be done by a certified technician
or electrician to ensure adherence to the applicable electrical safety wiring
regulations and installation codes. Failure to follow these instructions can
damage the unit and could also result in personal injury or loss of life.
CAUTION: B
efore beginning your unit Installation, please consider the following:
•T
he unit should be used or stored in an indoor area away from direct
sunlight, heat, moisture or conductive contaminants.
•W
hen placing the unit, allow a minimum of three inches of space around the
unit for optimal ventilation.
Note: The WP Battery Charger is designed to be permanently mounted.
Mounting the Charger:
• Choose an appropriate mounting location.
• For installing in an indoor location, the unit can be mounted in any direction.
• For installing in boat or marine environment, the unit can be mounted horizontally and
vertically (AC and DC panel facing downwards) only.
• Use the mounting template below to mark the positions of the mounting screws.
• Drill the 4 mounting holes and place the Charger in position and fasten the unit to the
mounting surface. See mounting location as below.
Chassis Grounding Connection:
DANGER: T
he unit chassis has to be grounded properly. Never operate the Charger without
proper grounding. Failure to do so will result in death or serious injury. Ground
connection to the charger must comply with all local and application-specific
codes and ordinances.
• Connect the unit’s chassis ground to the common ground point through the ground stud
located near one of the unit mounting slots. See image in Section 3.
DC Output Wiring:
WARNING: The DC wiring used must be of appropriate size. An individual over-current
protection device usually within 7 inches (17.8cm) of each battery bank is
12 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
required. A DC disconnect switch is also recommended. Both devices must
be rated for DC voltage and current and be rated to withstand the short circuit
current available from the connected battery bank. Both devices must match
with the size of the DC wiring.
Recommended Cable Length, Size and Required Fuse Size:
Wire Length
•
•
•
•
•
•
•
Wire Size (AWG/mm2) - Fuse Size (A)
WP-BC 12/20
WP-BC 12/40
WP-BC 12/60
5’ (1.5 m)
#10 / 6mm - 30A
#8 / 12mm - 50A
#6 / 16mm2 - 80A
7.5’ (2.2m)
#10 / 6mm2 - 30A
#6 / 16mm2 - 50A
#4 / 25mm2 - 80A
20’ (6m)
#6 / 16mm - 30A
#2 / 35mm - 50A
#1 / 50mm2 - 80A
2
2
2
2
emove the DC compartment cover by removing the two screws located on the top
R
surface of the unit near the AC wiring compartment.
Keep the connection between the battery and the charger as short as possible.
Connect one end of the positive wire (red wire) to the Bank_1 of charger positive terminal
with torque 4.0 ~ 5.0 N-m (35 ~ 45 lb-in) and the other end to the over current protection
device, then the DC disconnect device. Do not over tighten as this may result in damage
to the charger.
Connect another wire from the DC disconnect device to the battery bank.
For systems with multi-battery banks: Follow the same instruction as on Bank_1 and
connect to Bank 2 & 3 accordingly.
Prepare the negative wire (black wire) and connect to the negative terminal of the charger.
Connect the other end of the negative wire to all the negative terminals of the battery
bank(s).
Place the DC Compartment cover back to the original position and secure the cover using
the two screws provided.
AC Input Wiring:
WARNING: The AC wiring must be of appropriate size, and it must be protected by
an appropriate branch breaker (not provided) connected between the AC
source and the Charger.
A three color coded #14 AWG wire (L, N and GND) with a rated minimum of 75°C wire and a
minimum 12 inches in length must be used.
Before connecting AC wiring, make sure the AC source is OFF.
- Remove AC compartment cover by unscrewing the two screws located at the top of the AC
compartment cover.
- Remove the top section of the AC Input wire strain relief located at the bottom of the base
panel inside the AC wiring compartment by unscrewing the two strain relief mounting
screws.
- Use the provided butt-splices to extend the AC Input wires (L, N and GND) to the
customer-provided chosen AC wire.
- Feed the extended AC Input wire through the strain relief located at the bottom of the unit’s
base panel.
- Place the top section of the strain relief back to the original position and secure the AC
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extended wire by using the strain relief and secure with the two screws provided.
- Connect the other end of the extended AC wire to the chosen branch breaker and connect
it to the AC power source. Please verify all the connections from Charger AC Live wire
(black color) to Black AC extended wire, Charger AC Neutral (white color) to White AC
extended wire and AC Charger green wire to AC extended green wire.
Optional Remote Display Connection:
(see more details in the instructions provided with the Remote Display)
For use with one charger unit:
• To install the optional Remote Display in a specific location, the 6 pin “rollover” RJ12
cable (maximum length 25 ft.) provided with the Remote Display, is required.
• Install the rollover RJ12 cable in your desired location.
• Connect one end of the RJ12 cable to the Remote Display Port and the other end of
the cable to the COM_1 port on the Remote Display Panel. (Do not use ‘COM_2’ on the
Remote Display)
• The Remote Display is now ready for use.
• The RJ12 cable below may come with a ferrite bead at one edge. If so, we suggest
connecting that edge toward the unit.
Optional Battery Temperature Sensor (BTS) Connection:
For single charger operation:
• To install the temperature sensor, simply connect the RJ12 plug from the sensor to the
corresponding jack of the Temperature Sensor Port on the charger
• On the Temperature Sensor end, simply connect the ring terminal (lug) to the negative
terminal of the chosen battery bank. As Battery Bank 1 is for the main battery bank
charging, it is highly recommended to connect the Temperature Sensor to Battery Bank 1
when in use.
For parallel charger operation (by using two units of the same model):
• Two batteries Temperature Sensors are required.
• Connect the RJ12 plug from the Temperature Sensor 1 / 2 to the corresponding
Temperature Sensor Port jack on charger 1 / 2 respectively.
• On both Temperature Sensor ends, simply connect the ring terminals (lugs) to the
negative terminal of the main battery bank.
Test the Charger Connection:
• Switch AC branch breaker switch to ON.
• The display will turn on. Pressing the ‘Info’ key will toggle the display to show the factory
default setting. The charger is now ready to use.
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5. UNIT OPERATION
Understanding the Charging Mechanism
• The charger is a three-bank battery charger that is capable of charging a maximum of
three battery banks.
• The charger is designed to have Bank 1 charge the main battery bank. Always use Bank
1 first when connected to a single battery bank.
• At start, if the charger senses Battery Bank 2 and 3 have battery connected and the
battery voltage is greater than 11V, the charger will then concentrate on fully charging
Battery Bank 1 first until it reaches float stage. It will then switch to charge Battery Bank
2 and 3.
Or:
• If the charger senses either Battery Bank 2 or 3 have battery connected and the battery
voltage is below 11V, it will cycle to charge Bank 1 for 15 minutes then Bank 2 and 3
together for 15 minutes. When the charger senses both Bank 2 and 3 reach 13V, it will
then concentrate on charging Bank 1 until it reaches the float stage. After that, it will then
concentrate on recharging Bank 2 and 3 (together) to float stage.
• Once all three banks have reached the float stage, the charger will adjust the charging
voltage to the preset float voltage of the battery bank 1, and all three banks will be
connected in parallel for float stage charging. During the float stage charging stage, each
battery bank is isolated by an internal separation diode.
• In float stage, see the below chart for the maximum allowable current draw:
Maximum Float
Current
WP-BC 12/20-3
WP-BC 12/40-3
WP-BC 12/60-3
20 A
40 A
40 A
For charging GEL, AGM, Flooded batteries:
• The charger can be set to ‘Mode 2’, 2 stage charging (Bulk and Absorption stage charging
only- no float stage) or ‘Mode 3’, 3 stage charging – (Bulk, Absorption, and Float stage
charging).
• Each battery bank can have its own maximum charging current and absorption-to-float
mode current settings.
For charging Lithium batteries:
WARNING: F
IRE HAZARD! When using the Lithium mode to set the battery Charging parameters,
please consult the battery manufacturer on all voltage and current settings. Using wrong
setting to charge the Lithium battery may overcharge and damage the battery, resulting in
battery explosion and fire.
Charging the Lithium battery requires the user to set the charger termination current. The charging
process will terminate when the charging current drops to the set termination current.
This can only be set at Bank 1, it has its own charging voltage and current setting. It also requires the user
to set the charger termination current. The charging process will terminate when the charging current
drops to the set termination current.
For using Program mode for charging batteries:
The charger can be used as a constant voltage power supply that will deliver the preset output voltage
(13.3, 13.5, 13.7 V) with the maximum current setting. With this setting, only Bank 1 can be used and the
other banks are disabled.
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Understanding the Digital Display and the Function Keys during Normal Operation:
During normal operation, the display shows the related channel’s battery voltage, charging current,
and charging stage (‘bul’ – Bulk stage, ‘Abs’ – Absorption stage, ‘Flo’ – Float stage) alternately. When
the ‘INFO’ key is pressed, it displays other channel’s battery voltage only. When all channels reach
float stage, the display will show ‘Full’ indicating all the batteries connected are fully charged.
During the equalization operation on a flooded battery, the numerical section on the display shows a
flashing ‘Eq’ indicating the equalization process is in progress and does not show the battery voltage
or the charging current.
Understanding the Digital Display Function with no AC Input:
With the unit already turned off (by disconnecting its AC-Input power) and the display completely in
blank, press and hold the ‘INFO’ key for at least 3 seconds until you see something on the display. The
display will show the voltage on each battery bank (channel) alternately (one at a time), as well as the
charger software revisions (e.g. “u1.5” or higher). If you read “0.6V” or “0.7V” it would mean that there
is not any battery connected to that battery bank terminal.
This feature is useful to know what battery banks (channels) are actually connected to the unit.
Understanding the Function Key ‘INFO’, ‘NEXT’ and ‘SET’ during Charger Setting:
‘INFO’: Press and hold the key for longer than 3 seconds to enter the charger
setting mode and show function setting. Once the new setting is done, press
‘INFO’ again to exit the charger setting mode.
‘NEXT’: Press the key once to keep or save the chosen setting and change the
display to show the next menu to continue other settings.
Note: The selected setting will quickly flash 3 times to acknowledge the setting.
‘SET’: Press the key to view other available settings or Press and hold the key
for 3 seconds to activate or deactivate ‘Silent Mode’ – ‘Auto’ icon to show on
display (see more details in section 3 - ‘Digital Display‘).
Please note: on later editions of the remote display, ‘SET’ is replaced by ‘ESC’.
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Understanding the Three-Stage (Mode 3) Charging:
The Three-Stage Charging (Mode 3) has a Bulk, then Absorption, and then Float sequence. During
the Bulk stage, the battery accepts the maximum constant current from the charger. In the Absorption
stage, the battery voltage is held to constant voltage and the charging current will slowly reduce. In
Float stage, the charger continuously produces lower constant float voltage to fully top up and maintain
the battery in a fully charged stage.
The charger will automatically restart the full charging cycle if it senses any one of the battery banks is
discharged to lower than 12.5V or after seven days in float stage to refresh the battery banks.
Understanding the Two-Stage (Mode 2) Charging:
The Two-Stage charging is similar to the Three-Stage charging except there is no float stage after the
absorption stage. The charger will terminate the battery charging after Absorption.
The charger will automatically restart the full charging cycle if it senses any one of the battery banks
is discharged to lower than 12.5V, or after seven days since the last Absorption stage, to refresh the
battery banks.
Understanding the Battery Temperature Functions:
The optional Battery Temperature Sensor (Part Number 60201202) is highly recommended with the
charger to protect your battery and provide better charging voltage accuracy. It is recommended to be
installed on the main battery bank - Bank 1.
The sensor senses the battery temperature and will override the manual temperature setting and make
small adjustments to the charging voltage.
Battery
Temperature
< 25 °C
Battery Charging Voltage Adjustment from 25 °C normal setting
Flooded and GEL type
AGM type
+ 0.027 V /°C
+ 0.021 V /°C
25 °C
0V
0V
> 25 °C
- 0.027 V /°C
- 0.021 V /°C
When the battery sensor is not in use, you can also manually set the battery temperature. There are
three manual battery temperature settings on the unit (‘Lo’, ‘nor’ and ‘hi’). See below for voltage
adjustments for temperature compensation.
Temperature
Setting
Recommended
for Battery
Temperature
Low (Lo)
Normal (nor)
High (HI)
Battery Type
Voltage adjustment from
25°C normal setting
<5°C
(41°F)
GEL, Flooded
+ 0.675 V
AGM
+ 0.525 V
>5°C and <30°C
(>41°F and <86°F)
GEL, Flooded
0V
AGM
0V
>30°C
(86°F)
GEL, Flooded
- 0.27 V
AGM
- 0.21 V
Procedure to set or view the charger setting:
Follow the procedure or sequence in Appendix A1 and A2 to set or view the charger setting.
For GEL, AGM, Flooded battery type:
Parameters below are required for setting:
• Battery type (GEL, AGM, Flooded)
• Maximum Current setting (see table below)
WhisperPower Battery Charger
12 V 20 - 40 - 60 A 17
• Absorption to float mode current setting (see table below)
• Charging stage (Mode 3: 3-stages, Mode 2: 2-stages)
• Battery temperature (low, normal, high temperature)
The following table shows the maximum available charging current and its related available
Absorption to Float mode current.
Model
WP-BC
12/20
WP-BC
12/40
WP-BC
12/60
Maximum
Current Setting
Absorption to Float
Mode Current Setting
* 20A
* 1A / 2A / 4A
15A
10A
5A
* 40A
20A
10A
5A
0.75A / 1.5A / 3A
0.5A / 1A / 2A
0.3A / 0.5A / 1A
* 2A / 4A / 8A
1A / 2A / 4A
0.5A / 1A / 2A
0.3A / 0.5A / 1A
* 60A
* 3A / 6A / 12A
40A
20A
5A
2A / 4A / 8A
1A / 2A / 4A
0.3A / 0.5A / 1A
Note: * Recommended setting (Factory Default Setting)
For Lithium battery type:
Parameters below are required for setting:
• Charging Voltage (13.9 - 14.4V)
• Maximum Charging Current (see table below)
• Termination Charging Current (current to define when the charging process will
terminate)
The following table shows the available charging voltage, maximum charging current, and the
available termination charging current.
Model
Charging
Voltage
WP-BC
12/20
14.2V /
14.3V / 14.4V
WP-BC
12/40
WP-BC
12/60
14.2V /
14.3V / 14.4V
14.2V /
14.3V / 14.4V
Maximum
Termination
Charging Current Charging Current
* 20A
* 1A / 2A / 4A
15A
0.75A / 1.5A / 3A
10A
0.5A / 1A / 2A
5A
0.3A / 0.5A / 1A
* 40A
* 2A / 4A / 8A
20A
1A / 2A / 4A
10A
0.5A / 1A / 2A
5A
0.3A / 0.5A / 1A
* 60A
* 3A / 6A / 12A
40A
2A / 4A / 8A
20A
1A / 2A / 4A
5A
0.3A / 0.5A / 1A
18 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
Program (Power Supply) type:
Parameters below are required for setting:
• Supply Voltage 13.3, 13.5, 13.7Vdc
• Maximum available current (see table)
The following table shows the programed voltage and the maximum current setting.
Model
Program Output Voltage Setting
Max. Current
WP-BC
12/20
13.3V/13.5V/13.7V
20A/15A/10A/5A
WP-BC
12/40
13.3V/13.5V/13.7V
40A/20A/10A/5A
WP-BC
12/60
13.3V/13.5V/13.7V
60A/40A/20A/5A
Procedure to Equalize Flooded Battery:
DANGER: E
xplosion Hazard. The battery generates explosive gasses during equalization.
Follow all the battery safety precautions listed in the manual.
DANGER: Explosion Hazard and Risk of Battery damage. When using the equalization mode,
the user has to be sure the battery connected to the channel is a flooded battery type.
Equalizing a non-flooded battery may overcharge it and cause the battery to explode.
CAUTION:Risk of Battery and Equipment damage. Only a Flooded lead-acid battery can be
equalized. Consult your battery manufacturer or read the battery manual when you
try to equalize your batteries. Disconnect any DC load connected to the battery, as
during equalize mode, the charger will produce 15.5V to the batteries. You must
monitor the battery specific gravity throughout the equalization process to determine
the end of the equalizing cycle.
Before setting the equalization mode on the specific channel, please be sure the channel chosen
for battery equalization is for a flooded battery type. When the battery equalization is started, the
charger will automatically fully charge the selected channel first and will execute equalization for
one hour. Check the battery electrolyte level during the equalization period. If necessary, refill
with distilled water only. All cells should have similar electrolyte levels. If distilled water is added,
batteries must undergo a complete charge cycle. The charger cannot determine when to terminate
the equalization of the battery. A one hour time-out is set and this is used as a safety feature to
require the user to continually re-activate it as necessary after checking batteries manually.
During equalization mode the other two banks are disabled.
Use the following procedure to setup the charger for battery equalization.
WhisperPower Battery Charger
12 V 20 - 40 - 60 A 19
Understanding the Silent Mode Function
The charger also comes with another unique ‘Silent’ Mode function that will stop the internal
fan operation.
Tips: Use this function during nighttime or when a quiet environment is needed. Please also
note that the charging time will increase in this mode because the charger is not running
at maximum power (it is de-rated).
- This function can switch to ON or OFF at any time during the charging period.
- To set this function, press and hold ‘SET’ key for 3 seconds to execute the ‘Silent’ Mode.
The ‘Auto’ icon will show on the display.
- To turn this function off, press and hold the ‘SET’ function for 3 seconds to turn off ‘Silent’
Mode. The ‘Auto’ icon on the display will turn off and the charger current and the fan speed
will return to normal.
Also; the charger will automatically depart from Silent Mode after 12 hours from being set.
Understanding the Protection Features
Derating the Charging Current: When the charger senses the environmental temperature is
above 50°C, the maximum charger current will de-rate to 1/2 of the value (A02 warning code
will display). The charger will recover automatically back to the maximum charging current
when the environmental temperature drops to below 45°C.
Over Temperature Shutdown: When the charger senses the environmental temperature is
above 60°C, the charger will shut down. It will recover automatically when the environmental
temperature drops to below 45°C.
Battery Reverse Polarity: When a reverse polarity is connected to the battery bank, Fault Code
E03 on display will appear. In some case, the user replaceable DC fuse located near the DC
Output terminals may blow and Error code E08 will display.
AC Input Voltage Protection: The charger will shut down when it senses the AC input voltage is
outside of the operating range. A fault code will display. The charger will recover automatically
when it senses the AC input voltage has returned to the normal operation range.
20 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
Disconnecting the Battery Bank: To avoid any spark on the battery terminal, always disconnect
AC Input before removing or disconnecting the battery.
BTS Shutdown (with optional BTS in use): To avoid any battery damage especially when a
Lithium battery is used, the charging cycle will be terminated when the optional BTS senses the
battery temperature is above 60 C or below 0C.
Charging Dead Batteries
The charger is designed to charge batteries with the voltages on their terminals greater than
2.5Vdc.
Understanding the Error Codes
Error codes will be shown on the display when either an internal fault such as high internal
temperature or external fault like AC input voltage out of range is detected. The unit will shut
down.
WhisperPower Battery Charger
Code
Condition
12 V 20 - 40 - 60 A 21
Corrective Action
A01
Temperature Sensor (BTS) is defective.
Check and or replace the sensor.
E01
Unit shutdown due to low AC Input
(< 85 +/- 5Vac)
Check AC input source. The unit will
automatically recover when the AC Input
voltage return to > 108 +/-5Vac
E02
Unit shutdown due to high AC Input
(>270 +/- 5Vac)
Check AC input source. The unit will
automatically recover when the AC Input
voltage returns to < 260 +/-5Vac
E03
Battery is connected backwards
Check all battery connections
E04
Charger Internal temperature is too high and it has to shut
down. The unit will automatically recover when the unit
cools down.
The ventilation of the unit is blocked or the
environmental temperature is high. Reduce
charging current or improve the ventilation near
the unit.
E05
Not used.
E06
For non- Lithium Battery type setting:
High battery temperature >70 °C (158°F) is sensed by the
BTS when installed. The unit will shut down. The unit will
automatically recover when the battery temperature has
reduced to 60°C (140°F).
For Lithium battery type setting:
High battery temperature >60 °C (140°F) is sensed by the
BTS when installed. The unit will shut down. The unit will
automatically recover when the battery temperature has
reduced to 55°C (131°F).
Check the battery, charger setting, and its
environment.
E07
For non- Lithium Battery type setting:
Low battery temperature < -25°C (-13°F) is sensed by the
BTS when installed. The unit will shut down. The unit will
automatically recover when battery temperature reaches
-20°C (-4°F).
For Lithium Battery type setting:
Low battery temperature < 0°C (32°F) is sensed by the
BTS when installed. The unit will shut down. The unit will
automatically recover when battery temperature reaches
5°C (41°F).
It is not recommended to charge the battery at
low temperatures.
E08
DC Output fuses are blown.
Check battery connection and replace the fuse
with the same type and rating.
E09
Unit shutdown due to high battery voltage (> 17 Vdc). The
unit will automatically recover when battery Voltage is
reduced to <16Vdc.
Check battery and charger settings. Check also
if there is any other DC supply connected to the
battery banks.
22 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
6. SPECIFICATIONS
WP-BC 12/20-3
Charger Output:
20A
WP-BC 12/40-3
WP-BC 12/60-3
40A
60A
Output Current (Maximum)
Output Voltage Range:
Charge
14.2 – 15.5 V
Float
13.4 - 13.8 V
Equalize (Flooded Battery)
16.0 V
Three stages (Bulk/Absorption/Float)
Charging Control
Two stages (Bulk/Absorption)
DC Output Bank
Three (CH1, CH2, CH3)
Selectable Battery Type
Gel, AGM, Flooded, Lithium, Program
Parasitic Current
< 2 mA
Charger Input:
AC Input Voltage (Nominal)
100, 120, 220, 230, 240 VAC
AC Input Operating Range
90 - 250 VAC
AC Input Frequency Range
Power Consumption (Full Load)
47 - 63 Hz
350W
Power Factor Correction
700W
1050W
Yes
Charger Efficiency
> 82%
Protection and Features:
Reverse Battery
Yes, unit shutdown
Over Charge
Yes, unit shutdown
Over Temperature
Yes, unit de-rated and shutdown
Output Short Circuit
DC Fuse
Cooling
Temperature Setting
Battery Temperature Sensor Port
Remote Display Port
Yes, unit shutdown
2*15A, 32V
2*30A, 32V
3*30A, 32V
Forced air ventilation
Hot, Normal, Cold (with no sensor connected)
RJ12 (optional battery temp. sensor use)
RJ12 (optional display panel use)
Display:
LCD Display (with back lighting)
Warning and Fault Code
Charging status, Battery Voltage
A01, E01-09
AC Input and DC Output Connection:
AC Input Connection
Hardwire or AC Cord
DC Output Connection (POS)
Heavy Duty Studs (3 banks)
DC Output Grounding (NEG)
Single Heavy Duty Common Ground Stud
Environmental and Operating Temperature:
Storage Range
-40° to 70° C (-40° to 158° F)
Operating Range
-20° to 60° C (-4° to 140° F)
Humidity
5-95%, RH non-condensing
Ingress Protection
IP32
WhisperPower Battery Charger
12 V 20 - 40 - 60 A 23
Based Unit Weight and Dimensions:
WP-BC 12/20-3
5.3lb., 11.6 x 8.1 x 3.4 inches (2.4kg, 295 x 206 x 86mm)
WP-BC 12/40-3
5.7lb., 11.6 x 8.1 x 3.4 inches (2.6kg, 295 x 206 x 86mm)
WP-BC 12/60-3
8.8lb., 14 x 8.1 x 3.8 inches (4.0kg, 356 x 206 x 99mm)
Regulatory Compliance:
Standards/Safety (North America)
Approved to UL1236 including the marine supplement
UL1564
CSA C22.2 107.2-01
Standards/Safety (European Union)
CE marked for the low voltage directive 2006-95-EC
Complying with EN60335-2-29 battery chargers
Approved to IEC60529:2001, IP32 ingress protection level
Standards/EMC (North America)
Standards/EMC (European Union)
Class B according to FCC part15B and ANSI C63.4
CE marked for the EMC directive 2004-108-EC
Complying with EN55014-1, EN55014-2, EN61000-3-2, and
EN61000-3-3 (as equivalent IEC standards series)
Note: Specifications are subject to change without notice.
24 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
7. WARRANTY
Five Year Limited Warranty
The limited warranty program is the only one that applies to this unit, and it sets forth all the
responsibilities of Whisper Power BV. There is no other warranty, other than those described
herein. Any implied warranty of merchantability of fitness for a particular purpose on this unit
is limited in duration to the duration of this warranty.
This unit is warranted, to the original purchaser only, to be free of defects in materials and
workmanship for one year from the date of purchase without additional charge. The warranty
does not extend to subsequent purchasers or users.
Manufacturer will not be responsible for any amount of damage in excess of the retail
purchase price of the unit under any circumstances. Incidental and consequential damages
are specifically excluded from coverage under this warranty.
This unit is not intended for commercial use. This warranty does not apply to damage to
units from misuse or incorrect installation/connection. Misuse includes wiring or connecting
to improper polarity power sources.
RETURN/REPAIR POLICY:
If you are experiencing any problems with your unit, please contact our customer service
department at [email protected] or phone +31 (0) 512 571 555 before returning
product to the retail store. After speaking to a customer service representative, if products
are deemed non-working or malfunctioning, the product may be returned to the purchasing
store within 30 days of original purchase. Any defective unit that is returned to manufacturer
within 30 days of the date of purchase will be replaced free of charge.
If such a unit is returned more than 30 days but less than one year from the purchase date,
manufacturer will repair the unit or, at its option, replace it, free of charge. If the unit is
repaired, new or reconditioned replacement parts may be used, at manufacturer’s option.
A unit may be replaced with a new or reconditioned unit of the same or comparable design.
The repaired or replaced unit will then be warranted under these terms for the remainder of
the warranty period. The customer is responsible for the shipping charges on all returned
items.
LIMITATIONS:
This warranty does not cover accessories, such as adapters and batteries, damage
or defects result from normal wear and tear (including chips, scratches, abrasions,
discoloration or fading due to usage or exposure to sunlight), accidents, damage during
shipping to our service facility, alterations, unauthorized use or repair, neglect, misuse,
abuse, failure to follow instructions for care and maintenance, fire and flood.
If your problem is not covered by his warranty, contact our customer service department
at [email protected] or phone +31 (0) 512 571 555 for general information if
applicable.
WhisperPower Battery Charger
12 V 20 - 40 - 60 A 25
26 WhisperPower Battery Charger
12 V 20 - 40 - 60 A
Page 20
WhisperPower Battery Charger
Appendix B
Page 21
12 V 20 - 40 - 60 A 27
Enjoy Green Energy
WhisperPower BV
Kelvinlaan 82,
9207 JB Drachten
The Netherlands
www.whisperpower.com
[email protected]