LIMITED WARRANTY For one (1) year from the date of purchase, The Guest Co., Inc. will, at its discretion, repair or replace for the original consumer, free of charge, any part or parts found upon examination by Guest Co., Inc., 48 Elm St., Meriden, Connecticut to be defective in material or workmanship or both. Proof of purchase required. All transportation charges under this warranty must be borne by the consumer. I THERE IS NO OTHER EXPRESSED WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF PURCHASE. THIS IS THE EXCLUSIVE REMEDY AND CONSEQUENTIAL DAMAGES ARE EXCLUDED WHERE PERMITTED BY LAW. CUSTOMER SERVICE If you, our customer, have any questions concerning Guest products, parts or warranties, please contact our Service Department Monday through Friday between 9:00 AM and 4:00 PM Eastern Time. MODEL 2815M (203)-238-0550 (203)-634-1696 fax BATTERY CHARGER The Guest Co. 48 Elm St. Meriden, CT 06450 USA INSTALLATION AND OPERATION INSTRUCTIONS FOR MODELS 281 5M11 15 AND 281 5M123D I A Valley Forge Company Writefor your free copy ofthe new GUEST catalog. ShipWrite 4. Services 1-24020 (formerly 2615AM) I5AMP,2-BANK IMPORTANT! READ THESE INSTRUCTIONS BEFORE INSTALLING AND USING THIS PRODUCT. Keep these instructions for future reference Description Specifications The Guest 2815M ChargePro is a solid-state “3-stage” battery charger and is lightweight, silent and completely automatic. It can produce a full 15 amps of 12 volt DC charging current while using much less AC current than other chargers. This revolutionary new design can rapidly recharge and individually maintain 2 separate battery banks at one time. If a DC short or overload occurs, the charger will reduce its output voltage to a safe level, then automatically return to normal after the overload is removed. Its water resistant polycarbonate housing and urethane coated circuitry make it ideal for harsh environments. Every Guest 28l5M charger is tested under load before shipment to assure superior reliability. Total output current maximum: “float” mode: Output voltage: with 15 amp load: finish (“float”) voltage: Input voltage 2815M/1 15: Input voltage 2615M/230: Max. AC draw at 115 volts: Housing dimensions Application Diagram 1 15 amps at 12 volts DC 0.1 to 0.3 amps at 13.! volts DC 12 volts DC minimum 13.5 volts DC (+7- 0.1 volts DC) 90 to 140 volts/SO or (0 Hz AC 190 to 240 volts/SO or 60 Hz AC 3 amps 9”H x 7 7/8”W x 4”D - - Guest 2815M charging method This battery charger is ideal for a wide variety of installations using 12 volt lead-acid or gel-cell batteries. Some of the most popular battery configurations are: • • Two Group 24 batteries Two Group 27 batteries • One Group 4D battery and one Group 24 battery Installations using more or larger batteries are possible, but it may require a longer time to recharge the batteries in these installations. Longer recharging times can also result if there is equipment on board that requires substantial amounts of DC current while at dockside, such as: • a DC only refrigerator or ice maker • a DC only air conditioner or heater a large number of 12 volt DC lights in use Iwo different versions of the Guest 281 5M are available: • The model 2815M11 15 for 115 volt AC input, and • The model 2815M1230 for 230 volts AC input. Both versions will function with either 50 Hz or 60 Hz AC inputs. —1— Time 0 > C) 0 V 16 15 14 ~V~V~VV~ 13 12 11 ~~VV~~VV 10 9 8 V 7 6 5 4 3 2 1 V V 01 01 01 01 01 DC Amps J RBuIk ~Absorbtion 0 Float This device meets or exceeds FCC Part 15 Standards elating to RF interference. This device is not intended for use with combination 12/24 volt battery systems. If your vessel does not already have an ABYC app’ oved AC dockside power system, The Guest Company strongly recommends that you consult with a qualified marine ~1ectrician before installing this device. Improper AC conne tions can cause physical injury or damage to your vessel. -2- Checklist for required tools and mate rials Operation When the 2815M charger senses a drop in battery voltage, it automatically increases its output to re-charge the battery. By using a sophisticated 3 stage charging method, it recharges your batteries in the fastest, healthiest way. The amp meter on the front of the charger shows the total combined charging current during the first and second charging stages, (“bulk” charging and “absorption” charging). When the low battery approaches full charge, the charger reduces its output to a “float” charging rate, indicated by the green LED light. This low float voltage gently “tops off’ your batteries, then keeps them fully charged and ready for use without overcharging. The total 15 amp output of this charger is divided between both ofthe batteries connected to it, however the charge being applied to each battery is individually regulated. When using the 281 SM to charge a single battery, a jumper wire, (not included), must be connected between the two DC positive (+) outputs ofthe charger. (See page 10.) The Guest ChargePro 281 SM battery charger is fully automatic, requires no maintenance, and can be left unattended indefinitely. However, the electrolyte (battery acid) in lead-acid batteries can gradually evaporate, particularly in warm climates. Check your batteries once a month as a part ofyour maintenance routine. )( Tools Electric drill with 1/4” and 1/16” drill bits Wire cutting and crimping tools 2 Safety glasses, work gloves, and long sleeved shirt Additional materials 4 4 20 20 1 6 as ~i as req. Overload Protection Ifan electrical overload(excessive demand) occurs in the DC system connected to this charger, it will reduce its output voltage to a safe level. In the event of a dead short, the charger’s output voltage will effectively be zero volts. Once the overload or short is removed, the 281 SM will automatically resume normal operation. -3- 1/4” slotted screwdriver 5/16” and 3/8” socket wrenches or nut driven Portable DC volt meter 4 3 1 #10 SS hex head or round head machine bolt’ (Bolt length = mounting surface thickness ph s 1”) each #10 SS flat washers, lock washers and hex nuts. 7” cable ties w/mounting holes (cx Beckson L-7M1-I) # 8 x 3/4” SS pan head self-tapping screws (for fastening cable ties to mounting surface). AC wiring 5 amp AC circuit breaker or fuse (if one is rot already installed and available in your Main AC panel) #8 ring terminals (to attach the AC input wires to the charger and to the main AC panel). 3 conductor, 14 gauge Marine UL listed AC cable to bring powerfrom your AC Main panel to the charger. DC wiring Tinned, stranded copper wire to connect the charger’s DC outputs to your batteries. (Red wire for positive (+) connections and black wire for ne~ative (-) connections). Use the table “DC wire size” on page 8 to determine the correct diameter wire to use ror your installation. #10 ring terminals to attach DC output wires to charger. 5/16” ring terminals (for connecting the 1)C output wires to the batteries’ positive (+) terminal pcsts). ring terminal to fit the engine’s negative (-) ground post -4- Installation Preparing the mounting location 1. Hold the battery charger against the surface wh ~re you are planning to mount it. (Be sure that you will bc able to Before beginning this installation - drill holes through this surface later without damage to wiring, tanks or other equipment.) Using a penc:1, mark • Open engine hatches and operate bilge blowers for 10 minutes to remove dangerous fumes and hydrogen gas. the locations of the battery charger’s four mounting holes onto the mounting surface • Disconnect all AC power sources. • Disconnect negative battery cables from all batteries. • Wear safety goggles, gloves and long sleeved shirt when drilling or while handling batteries. Choosing a mounting location 1. Mount this charger in an upright position only, with the aluminum cooling fins running vertically. It is important that the charger have at least 6 inches of unrestricted airflow on all sides for effective cooling. Do not install onto a carpeted, upholstered, or varnished surface. 2. Although this charger is ruggedly designed, avoid mounting it in an areathat is open to rain, snow or spray. 3. Avoid mounting this charger within 3 feet of a compass, TV or FM radio. 4. Select a mounting location which will allow the shortest DC wires between the charger and the batteries. 5. Do not mount this unit directly over your batteries because their corrosive fumes can damage the circuitry inside this charger. 6. Be sure that the mounting location will allow access to the connections on the charger after it is mounted. -5- 2. Drill four 1/4” holes through the mounting surface at the locations you marked with pencil. Note: Do not mount the charger until ~~you have made thefollowing electrical connections Electrical connections Installing the Guest 2815M1115 or 2815M/230 ~equires making two different types of electrical connections: the DC (12 volt battery system) and the AC (dockside power) Planning the DC connections You can configure the Guest 281 SM charger to main:ain one or two separate 12 volt batteries. There are several ways to connect this charger into your present 12 volt system. The simplest and most widely used connection metho i is: 1. Run one red DC wire from each of the charger’s :wo DC positive (+) outputs to the positive posts ofeach battery. When charging a single battery, you must conncct both charging outputs to the battery. 2. Connect a black DC wire from the charger’s ommon negative (-) terminal to the engine block’s ommon negative ground terminal. This method is illustrated in diagram 2 on page 7. -6- Making the DC connections Planning the DC connections (cont.) This is the most common type ofbattery charger installation: 1. Use the following table to determine the gauge (thickness) of the wire you will need to carry the current from the charger to your batteries safely and efficiently. Diagram 2 Recommended DC wire sizes Length of wire, (in feet) as measured from the battery chargerto the farthest battery and back to the charger red Two 12 volt batteries --~---- 12 volt DC negative (-) ground Two alternative methods for making the DC connections are: I. connecting the DC positive (+) outputs of the charger to the battery connections on your battery switches or 2. connecting the DC positive (+) outputs of the charger to the output posts of your battery isolator. (Do NOT connect the charger’s outputs to an isolator’s inputs.) These methods are only recommended if your 281 SM will be mounted much closer to your battery switches or battery isolator, than it will be to your batteries. For sample diagrams of these types of installations, refer to Guest document 1-21681. This is included with all Guest battery switches and isolators, and is available on request. -7- (maximum 3% voltage drop) Max. amps 10 feet 15 feet 20 feet 25 feet 30 feet 40 feet 50 feet 10 l4ga. l2ga. lOga. tOga. tOga. 8 ga. 6ga. 115 I2ga. lOgs. lOga. Sga. 8ga. 6ga. 6ga. 20 10 ga. 10 ga. 8 ga. 6 ga. 6 ga. 6 ga. 4 ga. 25 10 ga. 8 ga. 6 ga. 6 ga. 6 ga. 4 ga. 4 ga. 30 10 ga. 8 ga. 6 ga. 6 ga. 4 ga. 4 ga. 2 ga. 40 8 ga. 6 ga. 6 ga. 4 ga. 4 ga. 2 ga. 2 ga. 50 6 ga. 6 ga. 4 ga. 4 ga. 2 ga. 2 ga. 1 ga. from Section E9, table Vii ofthe American Boat and YachtCouncil (ABYC) standards and Recommended Practices for 5mail Craft’ 2. Find a path for the DC wires between the chargt~rand your batteries. Remember to route the wires away from hot surfaces or other areas where the wires could be damaged. Make sure you will be able to fasten a ceVble tie to a solid surface at least every 18 inches throughout the length of the wires to support them according to ABYC standard E-9. 1 5h. -8- I The DC connections (continued) 3. You will also need to establish a path between the charger’s common DC negative output and the common negative (-) engine ground connection. This is normally Remove the two screws on the lower face of the expose the wiring terminals. The AC and DC terminals are arranged as shown here: Diagram 3 where the batteries’ negative cables connect to the engine block. (When installing this unit in outboard powered boats, the DC negative (-) charger output will be connected directly to the negative (-) terminal of one or both batteries.) I Do not connect any wires to the batteries or to the charger until AFTER you have cut each one to size, crimped an appropriate connector onto each end and securely mounted the wires with the screw-down cable ties. This can help to prevent accidental short-circuits during your installation. 4. After you have determined an appropriate path for the DC wires to each battery, cut them to size, leaving three feet extra. Strip 3/8” of insulation from the battery ends of the red wires. Test fit a 5/16” ring terminal onto the threaded positive (+) posts ofyour batteries. Remove the ring terminal from the battery post and crimp or solder it onto the battery end of the red wire. 5. Repeat step 4 for the red positive wire leading to the other battery ‘s positive post~. 6. Repeat step 4 for the black wire, using a ring terminal that will fit your engine’s negative ground terminal. 7. Use screw mounted cable ties or wire straps to fasten all the wires between the batteries and the charger onto solid surfaces. Avoid running wires over sharp edges or near areas ofextreme heat. -9- to Battery 2 POSITIVE POSITIVE BLACK to NEGATIVE DC ground (engine block) NOTE: When charging only one I a 12 ga. jumper wire must be a between output posts DC #1 and DC This is the correct way to attach terminals to the Diagram 4 II 1l~ -10- to Making the AC connections ~AUflON! If your vessel does not already have an ABYC approved AC dockside power system. The Guest Company strongly recommends that you consult with a qualified marine electrician before installing this device. Improper AC connections can cause serious physical injury and may damage your vessel. Before making any AC connections, be certain that all sources of AC current have been safely disconnected from the vessel. DON’T ASSUME! To use a grounded 3-prong outlet Do not apply AC power until after you have made all cf the DC connections. Use AC sockets with a ground fault interrupter (GFCI) breaker. Do not use 2 blade ground adapter plug i. 1. Use only a heavy duty 3 conductor AC cord such a:; a Guest part # U-2554 or Radio ShackTM part # 278-1258. 2. Crimp #8 ring terminals onto the three AC wires. 3. Make the AC connections on the front of the charger according to diagram 3 on page 10. 4. Do not plug the charger’s cord into an AC outlet until after you complete the following steps. The Guest 2815M/1 15 and 2815M/230 chargers each require three Finishing the wiring connections AC connections. These connections are: 1. Connect the DC output wires to the DC output ten ninals of the charger as shown in diagram 3 on page 10. Use a 3/8” socket wrench or nut driver. Do not over tighten. 2. Connect the other end ofthe black (negative) DC ~ ire to the engine’s common negative ground, or to the negativ~posts of both batteries. • a Ground wire (normally green or green/yellow), • a Neutral wire (normally white or blue) and • a Hot or Line wire (normally black or brown). To hard wire the charger into your AC system 1. Determine a safe path for the AC wiring between the charger and Main AC panel. Avoid hot or sharp surfaces. 2. Fasten all wiring onto solid surfaces using screw-mounted cable ties or cable straps every 18 inches. 3. Attach #8 ring terminals onto both ends of the AC wires by crimping or soldering. 3. Install a 5 amp AC circuit breaker or fuse into the AC Hot wire (black or brown), in your Main AC panel. Attach the AC Hot, Ground and Neutral wires from the charger to the appropriate connection points at the Main AC panel. 3. Connect the other ends of the red (positive) DC wires to the positive posts of your batteries. NOTE: A small spark may occur. This is normal. 4. Confirm that all sources of AC power are turned off. Connect the AC input wires from the AC Main panel to the AC terminals on the charger as shown on diagram 3 on page 10. Use a 5/16” socket wrench or nut driver. Do not over tighten. 5. Replace the rectangular cover plate over the screw terminals on the front of the charger, passing each wire through one of the notches in the cover plate. Attach the cover plate to the charger with the screws provided. You are now ready to fasten the charger onto mounting ;urface. -12- —11— r Mounting the Battery Charger Problem 1. Charger does not seem to be charging batteries. Fasten the charger onto the mounting surface as shown here: Diagram 5 Cause #10 lock washer #10 flat washer 2. The green LED light blinks and the amp me er porn er fluctuates rapidly. bolt #10 flat washer Fasten all wires leading from the charger onto the mounting surface using cable ties. Avoid any sharp edges that might cut the insulation ofthe wires. This completes your installation. 3. The green LED never turns on. After 24 hours, use a voltmeter to check the voltage at the positive and negative posts of each battery with the charger on. Each battery should read between 13.2 to 13.6 volts DC. Ifyou have large batteries, or a continuous DC load is present, measure the battery voltages after 48 hours. -13- 4. The amp meter does not move and the green LED does not light, ~ 5. The GFCI breaker, (Ground Fault Circuit Interrupter), turns off whenever the char er is turned on ~ I Sol~tion One or more defective or damaged batteries, 1. Test batteries and replace i necessary. 2. Charger has reduced its output voltage below charging level due to a DC overload or a DC short. 2. Remove the source of the overload or short, and th~n re-test the charger as described under ‘Operation” to confirm that it is charging properly. 1. Blown DC output fuses due to the charger being attached to the batteries backwards. I. To repla~efuses: a. Unplug AC power. b. Remove charger cover. A single battery has been connected to the charger without tying its two (+) positive outputs together with a jumper wire (Pg. 10) c. Inspect both fuses. d. If a fuse has blown, use ONLY u Buss ATO 20 amp as ~. replacement. I. This could be due to: 1. a. A dead short or overload, b. One or more bad batteries. c. A heavy DC load on batteries while charging. (such as lights, pumps, etc.) Disconnect the negative (-) DC cutput wire from the charger. Re-apply AC po’.ver. The green LED only should now light. If it does, the charger is OK. If not, contact The Guest Co. I. Confirm that AC power is available, 1. Connect AC power supply cr reset breaker, 2. Inspect the charger’s AC input wiring and wire terminals for damage or loose connections. 2. Disconnect all AC power s)urces, and then repair wiring. 3. 3. Component failure. Return i:harger to Guest Service department. 1. There is a problem in the charger’s AC connections or the AC power supply. I. Confirn’ 2. Testing your installation Activate the battery charger by re-connecting your dockside AC power. Observe the amp meter on the front of the charger. It should show that current is flowing into your batteries. (Turn on several DC lights if you are not sure if the meter is registering.) When the batteries have reached full charge, the green LED light on the front of the charger will turn on. II 1. (Note: Measure the voltages in your batteries as described under “Operation” to confirm that there is actually a charging problem.) #10 hex nut rubber washer (included) I 2. . Certain brands of GFCI breakers are unusually sensitive to “switching” style power supplies. -14- that the charger’; AC cord is intact, tien test the AC power sipply. 2., Contact Guest service for information.