CPS-UNIT2-DAA
30016911
CRISTEC
L'énergie embarquée
Documentation
C.P.S. Power unit
Range
™™™™™
12V – 40A
S.A. CRISTEC Industries
47, rue Pierre Mendès France
29000 QUIMPER
FRANCE
Tél : 33 (0)2.98.53.80.82
Fax : 33 (0)2.98.55.64.94
CPS-UNIT2-DAA
Page 2
CRISTEC
Operating Manual in English
Page 3
WARRANTY CARD
Page 24
Do not forget to fill in the warranty card and
send it back to us.
Page 3
CPS-UNIT2-DAA
CRISTEC
CONTENTS
DESCRIPTION
PAGE
Contents
3
n Introduction
4
4
4
4
4
5
6
1.1 Installation and operating manual
1.2 Validity of this document
1.3 Guarantee
1.4 Brief presentation
Installation and connection diagram
1.5 Reference standards applied
o Characteristics and operation
2.1 Technical characteristics
2.2 Charger operation
p Installation
3.1 Introduction
3.2 Items supplied
3.3 Additional supplies necessary for electrical installation
3.4 Special recommendations for installation
3.5 Commissioning
q Maintenance and repair of equipment
4.1 Introduction
4.2 Equipment maintenance
4.3 Equipment repair
r Safety
5.1 Standards references
5.2 Precautions relating to personnel safety
5.3 Precautions relating to protection against fire and explosion
s Appendice
7
7
10
12
12
12
12
14
16
17
17
17
17
18
18
18
18
19
Page 4
CPS-UNIT2-DAA
CRISTEC
n Introduction
1.1 Installation and operating manual
The present document applies to power unit in the CRISTEC CPS range of power
units listed below.
Power (Watts)
U/I Rating
Input Voltage
CRISTEC
Reference
480
12/40
230 VAC – 50Hz
SEEL006912
480
12/40
115 VAC – 60Hz
SEEL006961
This manual is intended for users, installers and equipment maintenance personnel
who must ensure they understand the present document before any intervention on
the power unit.
1.2 Validity of this document
This document is the property of CRISTEC; all the information contained in this
document applies to the accompanying product. The company reserves the right to
modify the specifications without prior notice.
1.3 Guarantee
Failure to comply with the rules for installation and operation cancels the
manufacturer's guarantee and absolves CRISTEC of all responsibility.
The period of guarantee is 36 months. It applies to parts and labour for an
equipment returned to the factory. Only parts acknowledged to have been
defective from the outset will be replaced under the guarantee.
Equipment which has been misused or damaged by errors in connections, impacts,
falls or which is defective from having been worked upon by persons other than those
authorized by CRISTEC.
Equipment which has been installed or operated at variance with procedures outlined
in the manual provided with each unit.
Under no circumstances, can any indemnity be granted by this warranty.
This warranty does not apply to the following terms :
n Transportation and packaging charges to and from the factory or authorized
service station.
o Damage sustained in shipment, apparent or concealed.
Claims for such damage must be reported and filed with the carrier by the person
receiving the equipment.
CPS-UNIT2-DAA
Page 5
CRISTEC
1.4 Brief presentation
Designed in partnership with the main French boat builders, the CRISTEC power
units allow to get in a single cabinet the on-board 230VAC or 115VAC protection
and a battery charger.
The power housings meet the European on-going rules. Compact and lightweight,
they provide practical entry for the cabling that reduces mounting time.
The user protection is insured by a 16A/30mA(230VAC) or a 32A/30mA(115VAC)
differential circuit breaker. The on-board utilisation outputs are protected by 3 10A
DPN thermo-magnetic circuit breakers (230VAC) or 3 16A DPN thermo-magnetic
circuit breakers (115VAC).
The charger function is made by a switch mode charger PCB from our classic CPS
charger range : Selective Dedicated Charge.
General characteristics :
- Input voltage : 115 or 230VAC +/-15%
- Input frequency : from 47 to 63 Hz
- Display : green LED for mains present
- Input and output cabling on gland
- Functioning temperature : 0°C/+40°C
- Matt black RAL 9011 and grey RAL 7035, salt atmosphere resistant
- CE standards: EN50081-1, EN50082-1, EN 55011, EN55022, EN60950 & ISO 13297
Charger characteristics :
- Input voltage : 115 or 230VAC +/-15% by internal switch
- Output voltage : 12VDC +/-1%
- Three automatic charge cycles : boost, absorption, floating
- Six hours programmable timed boost by internal switch
¾ Position "BOOST ON" for authorize boost
¾ Position "BOOST OFF" for inhibit boost
- Charge distributor incorporated into each battery output
- Specific output matched to the engine battery charging
- Selection of the level of charge according to the type of battery by internal switch
¾ Plomb/Antimoine (ANT)
¾ Plomb/Calcium (CAL)
- Internal potentiometer allows output voltage to be adjusted
- Protection against shorts-circuits and polarity reversal. Fuses on input and output.
- Low noise, thermostatically controlled electric fan
CPS-UNIT2-DAA
Page 6
CRISTEC
Characteristics distribution AC :
- General input protection by a 30mA / 16A or 32A differential circuit breaker.
- AC outputs : protected by 3 thermo-magnetic circuit breaker DPN 10A or 16A.
 When they leave the factory the chargers are configured as follows :
¾ Mains supply:
- 230 Vac for the model SEEL006912 (30mA / 16A differential circuit
breaker + 3 thermo-magnetic circuit breaker DPN 10A)
- 115 Vac for the model SEEL006961 (30mA / 32A differential circuit
breaker + 3 thermo-magnetic circuit breaker DPN 16A)
¾ Battery: Lead/Antimony
¾ Charging mode : Boost then automatic switch to Floating
¾ Output voltage setting in Floating:
Š at 13.8 V ± 1% off load
 Cable entry is via cable glands.
 Dimensions drawing : see appendice.
 Terminal drawing : see appendice.
 Fixing drawing : see appendice.
 Setting charger board drawing : see appendice.
1.5 Reference standards applied
The standards applied are:
¾ NF EN 60950 + A1 + A2 (October 93):
safety of information processing
equipment including electrical office
equipment.
¾ NF EN 50081-1 (June 92) EMC:
Generic standard for emissions
¾ NF EN 50082-1 (June 92) EMC:
Generic standard for immunity
¾ NF EN 55022 (December 1994):
Limits and methods for measuring the
characteristics of RF interference
produced by information processing
equipment.
Enacted at Quimper on: 2 March 2000
For and on behalf of CRISTEC SA,
Page 7
CPS-UNIT2-DAA
CRISTEC
o Characteristics and operation
2.1 Technical characteristics
2.1.1 Mechanical characteristics
All models have an IP20 protection rating. The are made of steel or of aluminium.
These parts are protected by several coats of epoxy paint.
Overall dimensions and weights of the various models are specified in the table
below :
Model
Length (mm)
Height (mm)
Depth (mm)
Weight (kg)
12V / 40A
310
315
100
5
Dimensions and fixing drawing : see appendice.
2.1.2 Input characteristics of charger
Model
12V/40A
Permissible Permissible Typical input
input
input
current rating
voltage
frequency
at 115 Vac
(Vac)
(Hz)
115 Vac
+/- 15% or
230 Vac
+/- 15%
single phase
by manual
selection
47 to 63 Hz
8A
Typical input
current rating
at 230 Vac
4.5A
Fuse
rating
and
format
10 A T
6.3 x 32
2.1.3 Output characteristics of charger
2.1.3.1 Output voltage of charger
The output voltages shown in the table below are obtained at 10% of rated power on
outputs BAT 1 and BAT 2. For those models having a BAT D output, the voltage
level is reduced by about 0.4 V.
Page 8
CPS-UNIT2-DAA
CRISTEC
These values are set in the factory with an accuracy of ± 1% and can be adjusted by
turning the potentiometer POT U (use a suitable tool for turning the potentiometer
screw).
They depend on the type of battery and mode of operation selected.
Model
Lead/Antimony
Battery
"Floating" Mode
12V / 40A
13.8 Vdc
Lead/Antimony
Lead/Calcium
Lead/Calcium
Battery
Battery
Battery
"Boost" Mode "Floating" Mode "Boost" Mode
14.5 Vdc
14.6 Vdc
15,4 Vdc
2.1.3.2 Output current of charger
The table below defines the maximum output current at rated output power as well
as the type and rating of the fuses placed in series with the charger outputs.
Model
Maximum output
current
Fuse rating
Type of fuse
12V / 40A
40 A
2x20 A
257020 LITTLEFUSE
2.1.4 Environmental specification
All chargers in the range meet the following characteristics:
¾ Storage temperature: - 20°C to + 70°C.
¾ Operating temperature: 0°C to + 40°C.
¾ Humidity: < 90% non-condensing
2.1.5 Protection and operating safety of charger
2.1.5.1 Input protection
Models 12V / 40A are fitted with one pole protection by 1 fuse F1 whose ratings are
given in section 2.1.2.
2.1.5.2 Output protection
Output protection is provided by a fuse placed in series with the "–" terminal of the
charger. The rating and type of this fuse are defined in the table in section 2.1.3.2.
Page 9
CPS-UNIT2-DAA
CRISTEC
2.1.5.3 Additional safety devices
All models are fitted with the following safety devices:
¾ Protection against input voltage surges by a Varistor (275 Vac).
¾ Protection against abnormal heating of the power semiconductors.
¾ Protection against polarity reversal (output fuse blows)
¾ Protection against overloads on the output by limiting the power to the rated
value for each model.
2.1.6 Options
The options do not form part of the basic power unit supply. They are available
from your reseller or from CRISTEC's Sales Department.
z Analogue voltmeter for displaying the charging voltage at the input side of
the charge distribution diodes.
Model
Charger 12V
Rated output
voltage (V)
12 V
Voltmeter reference
30008288
z Analogue ammeter for displaying the total battery charging current
Model
Maximum output
current
Ammeter reference
12V / 40A
40 A
30011514
z Battery temperature compensation
Probe length
Probe reference
1m
3m
SEEL006123
SEEL006124
CPS-UNIT2-DAA
Page 10
CRISTEC
2.2 Charger operation
2.2.1. Output voltage
The charger delivers a voltage suitable for recharging 1, 2 or 3 separate batteries.
All models (12V / 10A) are fitted with an output suitable for recharging the engine
battery (BAT D output).
2.2.2. Block diagram of charger
2.2.3. Principle of operation
The CPS range of battery chargers are designed on the basis of a high frequency
switching converter which transforms the ac signal into a regulated, filtered dc
voltage suitable for charging accumulator batteries.
2.2.4. Detailed operation
After the initial selection of input mains, type of battery and type of charge, battery
charger operation is entirely automatic.
2.2.4.1 Selector operation
z Mains voltage selector
The charger is fitted with an internal voltage selector enabling it to operate on 2
types of mains supply :
 European mains supply: 230 Vac – 50/60 Hz
 Other mains supplies (USA, etc. …): 115 Vac – 50/60 Hz
CPS-UNIT2-DAA
Page 11
CRISTEC
z Battery type selector
The charger is fitted with an internal selector enabling it to operate on 2 types of
battery just by changing a switch:
 Lead/Antimony battery: "ANT"
 Lead/Calcium battery: "CAL"
z Charge type selector
The charger is fitted with an internal selector enabling it to provide 2 types of
charging just by changing a switch:
 Charge in Floating mode: "BOOST OFF"
 Charge in Boost mode for 6 hours ± 30 minutes then automatic switch to
Floating mode: "BOOST ON"
NB: The Boost voltage off load is about 5% higher than the off load Floating
mode voltage.
2.2.4.2 Operation of the indicators
This indicator is fitted on the charger front panel and displays the unit's mode of
functioning. Differential circuit breaker ON.
z "Mains present" indicator
This indicator is extinguished in the following circumstances:
 Absence or degradation of the ac mains supply,
 Differential circuit breaker OFF or triped.
2.2.4.3 Special operation
z Special batteries
The factory settings are for standard use of Lead/Antimony and Lead/Calcium
batteries. Refer to a professional installer for special settings to match the battery
manufacturer's specifications, taking into account the special features of the
installation.
CPS-UNIT2-DAA
Page 12
CRISTEC
z Electricity generating sets
The CRISTEC battery charger is designed for use from an electricity generating
set.
In certain circumstances, electricity generating sets can generate large
overvoltages. Before connecting the charger, check that the charger is compatible
with the generator: power, voltage, voltage surges, frequency, current, …
p Installation
3.1 Introduction
This section deals with matters relating to charger installation.
Installation and operating the charger for the first time must be undertaken by an
electrician or professional installer in accordance with the standards in force (in the
case of pleasure boats, comply with the international standard ISO 13297).
The installer must take note of this operating manual and must inform users of the
matters relating to installation and safety contained in section 5.
3.2 Items supplied
CRISTEC supply items include the following elements:
¾ 1 metal case containing the battery charger electronic functions and circuit
breaker
¾ the present documentation (operating manual).
3.3 Additional supplies necessary for electrical installation
These items do not form part of CRISTEC's supply.
References to additional supply items which are necessary for correct operation of
the charger are defined in the following sections:
Any failure to comply with these provisions will result in cancellation of the
manufacturer's guarantee.
Page 13
CPS-UNIT2-DAA
CRISTEC
3.3.1. Cable connecting to the public mains supply or to an electricity generating set
Depending on line lengths, cables connecting to the ac mains supply MUST have a
cross-section equal to, or greater than, the values shown in the table below:
Model
Minimum cross-section
and types of cable
for 115 Vac
Minimum cross-section
and types of cable
for 230 Vac
12V / 40A
3 x 2.5 mm² HO7-VK
3 x 1.5 mm² HO7-VK
It is ESSENTIAL to use endfittings with insulated sleeves (in accordance with standard
NF G 63-023) for connecting the mains input.
The PE conductor (commonly called "earth" green/yellow wire) of the AC source
MUST be connected to the power unit on the terminal provided for this purpose.
3.3.2. Battery connection cable
Depending on line lengths, cables connecting to the batteries MUST have a crosssection equal to, or greater than, the values shown in the table below:
Model
Cross-section and type
of battery connection
cables
Type of terminal
Cross-section of cable and
diameter of the terminal hole
12V / 40A
16 mm² HO7-VK
16 mm² - 5 mm
It is ESSENTIAL to use the cable glands on the underside of the case in order to
prevent any damage to the cables on the metal edges of the case and to guarantee
double insulation between the live conductors and electrical earth.
3.3.3. Voltmeter and Ammeter link cable (only on certain models)
These cables must have a cross-section equal to, or greater than, 0.34 mm² and be of
type: KZ0506 - 600 V.
They must have endfittings with insulating sleeves in accordance with NF G 63-023.
It is ESSENTIAL to use the cable glands on the underside of the case in order to
prevent any damage to the cables on the metal edges of the case and to guarantee
double insulation between the charging circuit and electrical earth.
CPS-UNIT2-DAA
Page 14
CRISTEC
3.3.4. Installation earthing cable
The cable linking the installation to earth MUST be connected to the earth screw
situated inside the power unit.
The cable used must have a minimum cross-section of 2.5 mm², be of the type HO7VK and be fitted with a suitable terminal.
3.4 Special recommendations for installation
3.4.1. Case position
3.4.1.1. Preventing the charger overheating
The charger is designed to be mounted on a vertical wall as shown on
appendice drawing.
An area of 150 mm from the front and bottom of the case should be kept clear.
Cooling is provided by forced ventilation on certain models. The installer must
make the necessary arrangements to ensure that the temperature of the air at
entry is less than 40°C in extreme operating conditions.
Arrangements must also be made to ensure hot air can get away either side of
the power unit.
3.4.1.2 Preventing running water or spray falling on the power unit
The protection factor is IP20 and the power unit position must be chosen so as
to prevent any moisture or salt entering the power unit.
If this were to occur, the equipment would be irreversibly damaged and there
would be a potential risk to the user.
You are recommended to position the power unit in a dry, well-ventilated
location, away from any source of heat.
3.4.1.3 Arrangements for the batteries
Batteries connected to the charger are likely to give off explosive gases during
the charging phase.
You are therefore recommended:
 to ban the use of any equipment generating sparks and flames near to the
batteries.
 to position the batteries in a well-aired and ventilated location.
 to take note of the battery manufacturer's instructions when installing the
batteries.
CPS-UNIT2-DAA
Page 15
CRISTEC
3.4.1.4 Accidental leakage currents to earth
c Accidental leakage current between line and earth
Comply with standard NFC 15-100 in respect of precautions over
installation. Have the connection work done by an electrician or
professional installer.
d Accidental leakage current between charge circuit and earth
Detection of accidental leakage currents to earth must be provided by a
safety device outside the power unit (residual differential current device
or insulation monitor device).
The installer must ensure that the rating and nature of the protection are
appropriate for the risks.
Special precautions are recommended on any installation where there is a
danger of electrolytic effects.
Regulations require the presence of a battery cut-out on the output + pole
and on the output - pole.
3.4.1.5 Precautions regarding lightning strike
In geographic zones exposed to a high risk of lightning strikes, it may be
worthwhile fitting a lightning conductor on the inlet side of the power unit in
order to prevent the latter being irreversibly damaged.
3.4.1.6 Electromagnetic interference generated by the power unit
z Use screened cable for all connections (*). The screening at both the emitter
end and receiver end must be connected to earth.
z Make sure the length of the cables and screening connections are kept as
short as possible.
z Route the cables as close to earthed objects as possible ("flying" cables or
cable loops are to be avoided – fasten the cables against earthed objects).
z Separate the power supply cables from output cables.
z Separate power cables from monitor signal cables (minimum 200 mm).
z Cables must carry only the power unit power supply. Branch or bridging
connections in order to supply another equipment are to be banned.
(*) This is advice for installation and not an obligation. The electrician installer
will decide whether to use screened cable or not, based on the EMC
environment.
CPS-UNIT2-DAA
Page 16
CRISTEC
3.5 Commissioning
This section lists the operations to be performed in order to commission the power
unit. It is advisable to comply strictly with these instructions before switching on for
the first time.
3.5.1. Selecting the mains supply voltage
Selection of the input mains supply is made using the selector inside the metal
case.
Precautions to be taken in using this selector are as follows:
¾ There must be no ac voltage present when the selector is moved.
¾ Position the voltage selector as a function of the type of alternating
mains supply used.
If this selector is incorrectly set irreversible damage to the power unit may
occur.
3.5.2. Selecting battery type
Drawings in appendice show the position of the selector as a function of the
type of battery used.
Precautions to be taken in using this selector are as follows:
¾ You MUST check the compatibility of the selection and the type of
battery connected BEFORE you switch on.
3.5.3. Selecting charge mode
Drawings in appendice show the position of the selector as a function of the
type of charge used.
Precautions to be taken in using this selector are as follows:
¾ You MUST check the compatibility of the "BOOST ON" mode voltage
with the type of battery connected.
¾ During the winter period, or periods of prolonged power unit connection
to the batteries, if the charger remains switched on set the switch to
"BOOST OFF" as a matter of course.
¾ If using the "BOOST ON" function, the starter motor battery MUST be
connected to BAT D on models having 3 outputs.
¾ If the charger is supplying 1, 2 or 3 banks of batteries with a low rate of
discharge, you are advised to select the "BOOST OFF" mode.
¾ If there is instability on the alternating mains supply to the charger
(micro-breaks > 500 ms), the charger will re-initialise the Boost period
of 6 hours ± 30 minutes and, in time, result in battery deterioration. In
such circumstances, we recommend that you select the "BOOST OFF"
mode.
CPS-UNIT2-DAA
Page 17
CRISTEC
3.5.4. Verifying the charge voltage
Before connecting batteries to the charger, you MUST check battery polarity.
Check also the voltage of the batteries using a calibrated voltmeter. Too low a
voltage on certain types of battery can indicate irreversible damage and an
inability to take a recharge.
3.5.5. Connecting up the options
You MUST contact your reseller or CRISTEC's Sales Department.
q Maintenance and repair of the equipment
4.1 Introduction
This section deals with arrangements for maintenance and repair of the equipment.
Correct operation and the life of the product are conditional on strictly complying
with the recommendations below.
4.2 Equipment maintenance
z Disconnect the power unit from the alternating mains supply for all maintenance
operations.
z If the power unit is placed in a dusty environment, vacuum it periodically to clean
it since layers of dust might affect heat dissipation.
z Check the state of charge of the batteries every three months.
z An annual check that nuts and bolts are tight is necessary in order to guarantee
correct functioning of the power unit (especially in an environment subject to
vibration, shock, large changes in temperature, etc.).
z A complete technical examination by a CRISTEC recommended serviceman is
advisable every 5 years. This general technical examination can also be carried
out in our factories.
4.3 Equipment repair
z Disconnect the power unit from the AC mains supply and from the batteries
before carrying out any repairs.
z If a fuse has blown, make sure the replacement complies with the rating and type
of fuse recommended in section 2.1.
z For any other repair action, contact a reseller or CRISTEC.
CPS-UNIT2-DAA
Page 18
CRISTEC
r Safety
5.1 Standards references
z Class I equipment in accordance with standard NF EN 60950.
z Installation requirements are contained in standard NFC 15-100 and the specific
standard for "pleasure boats– electrical systems – Installation of ac distribution
system", reference ISO 13297.
5.2 Precautions relating to personnel safety
z Installation must be undertaken by an electrician or professional installer.
z The alternating mains supply must be cut off before any intervention on the
equipment.
5.3 Precautions relating to protection against fire and explosion
z Use the fuses defined in section 3.1.
z In the vicinity of the batteries:
¾ Ventilate the room,
¾ Do not smoke,
¾ Do not use a naked flame.
Page 19
CPS-UNIT2-DAA
CRISTEC
APPENDICE
Dimensions POWER UNIT 12V/40A
06906 07
Connecting fixing POWER UNIT 12V/40A
06906 08
Setting charger board 12V/40A
05389 08
CPS-UNIT2-DAA
CRISTEC
s Notes
Page 20
CPS-UNIT2-DAA
Page 24
CRISTEC
(à conserver précieusement)
(to be kept)
Référence de l'appareil (Model) : __________________________
Date d'achat (Purchase date) : ____________________________
N° de série (Serial number) : ______________________________
La garantie dont cet appareil fait l'objet traduit notre confiance dans la qualité des matériels et des hommes
qui l'ont constitué. La garantie CRISTEC protège votre investissement : lisez-la soigneusement.
Pendant un an à compter de la date d'acquisition, CRISTEC remplacera sans frais de main-d'œuvre, toute
pièce reconnue défectueuse, à son usine ou chez un de ses distributeurs agréés.
Pour que la garantie prenne effet, la carte de garantie doit être retournée remplie et convenablement
affranchie à CRISTEC, dans les 30 jours qui suivent la date de l'achat.
The warranty on the product reflects the confidence of is maker in the quality of materials and workmanship
that go into it. The CRISTEC warranty has been established to protect your investment. Please read it
carefully.
Within one year period from the original purchase, CRISTEC will replace, without charge for labor or
material, any part or parts in this equipment found to be defective in material or workmanship upon
examination at its factory or any authorized dealers or warranty stations.
Warranty conditions :
The warranty takes effect only if the warranty registration card has been fully and properly
completed and returned to CRISTEC within the 30 days after the purchase date.
CARTE DE GARANTIE
(WARRANTY CARD)
Référence de l'appareil (Model) : ___________________________________
Date d'achat (Purchase date) : _____________________________________
N° de série (Serial number.) :
Nom (Names) :
Adresse (Address) :
Rue (Street.) :
Ville (City) :
Code postal (ZIP code.) :
Pays (Country) :
CPS-UNIT2-DAA
CRISTEC
CRISTEC
L'énergie créative d'un constructeur
S.A. CRISTEC
47, rue Pierre Mendès France
29000 QUIMPER
FRANCE
Page 25