Chargetek TPRO-220 User manual

LIMITED WARRANTY
For two years from date of purchase, Chargetek Inc. will
at its discretion repair or replace for the original
consumer, free of charge any part or parts found to be
defective by Chargetek in workmanship or material.All
shipping charges under this warranty must be paid by
the consumer. Proof of purchase is required.
Thereisnootherexpressedwarranty.Implied warranties,
including those of merchantability and fitness for a
particular purpose are limited to two years from the date
of purchase. This is the exclusive remedy and
consequential damages are excluded where permitted
by law.
CHARGER OPERATION
The TPRO220 is fully automatic once installed properly. The
indictor lights (LEDs) informs the user of the progress of the
charging cycle and confirms proper connections. The charger
monitors each battery individually and charges each to full ca-
pacity. The charging current is distributed to the two banks as
determined by the state of charge of the batteries.
ELECTRICAL CHARACTERISTICS
AC Input Voltage Range: 100-132VAC
AC Input Current: 6A rms Maximum
Max. Charging Current: 22A(Fast Mode)
Max. Charging Voltage (Absorption Mode): 14.5-14.85VDC
Max. Float Voltage (Float Mode): 13.2-13.5VDC
LED INDICATORS
Charging Mode LEDs indicate the state of charge of the batter-
ies. The green Float light is the final charge state indicating the
batteriesarefully charged.Only oneChargingMode LED should
be on at any one time.
Charging Current LEDs indicate the amount of charging cur-
rent being delivered by the charger to all three outputs.
AC Power On LED indicatesAC power is applied to the charger
Charging Status LED indicates outputs are connected properly
to their respective batteries and are being charged. When prop-
erly installed all Charging Status LEDs should be on.
PROTECTION MODES:
Over Temperature: The TPRO220 will reduce its charging cur-
rent as its case temperature increases to insure proper operation.
In the event of a charger over temperature the unit will turn off
until it cools off and then restart automatically. This over tem-
perature condition is indicated by the AC Power on and Float
LEDs flashing. If the unit is operated in a very high ambient
temperature, it is possible for the temperature to increase fur-
ther, as indicated by theAC Power on and 14-20Amp Charging
Current LEDs flashing. In the rare event this condition occurs
the AC power and two Battery Banks should be disconnected
and reconnected once the charger has cooled off.
Over Voltage: The charger is equipped with an overvoltage pro-
tection circuit in the event of a regulation malfunction. The
charger will turn off if the overvoltage persists. The AC power
and two Battery Banks should be disconnected for 2 minutes
and reconnected to the batteries. An over voltage condition is
The TPRO220 is a sophisticated 20Atwo-bank battery charger.
It can be configured in a multitude of battery system configura-
tions and used as either an on-board or portable unit
Charging is controlled by an embedded microcontroller that
contains software developed and proprietary to Chargetek.This
electronic "brain" insures that all batteries will be fully and prop-
erly recharged regardless of the condition of any one battery.
The TPRO220 precisely controls charging voltage and current
to insure a complete recharge every time. The charger may be
left connected indefinitely to the batteries, maintaining full
charge at all times.
The TPRO220 utilizes state of the art high frequency power
processing that converts the AC line power to 12 VDC effi-
ciently and safely. The charger is completely waterproof and
sealed with UL approved 94VO flame retardant epoxy. This
sealing also provides extreme vibration and shock resistance
since the encapsulated unit is effectively a "brick".
indicated by the AC Power On and Fast LEDs flashing. If the
over voltage persists then the factory should be consulted.
Good battery maintenance procedures dictate that battery fluid
levels be checked on a regular basis, especially in high ambient
temperatures.
TPRO-220
INSTALLATION MANUAL
CHARGETEK
409 Calle San Pablo, Unit 104 ~ Camarillo, CA93012 ~ PHONE: [phone] FAX: [phone]
WWW.CHARGETEK.COM
10/25/09RevE.

INSTALLATION
LOCATION
Do not mount directly over or under a battery or onto a carpeted,
upholstered or varnished surface.
Install in an area where all charger electrical cords will avoid hot
surfaces such as exhaust pipes and moving parts such as fan wheels.
Operating ambient temperature is 15 to 130 degrees Fahrenheit.
Storage temperature is -20 to 160 degrees Fahrenheit.
Pick an area that will provide as much surrounding cooling
clearance as possible for maximum efficiency and shortest recharge
times.Maintain a 12 inchclearance around chargerandnever mount
in the vicinity of explosives, pressurized cans or other flammable
material.
MOUNTING
Wear safety goggles, gloves and a long sleeve shirt when drilling
mounting holes near a battery.
In most cases, #10 stainless steel mounting bolts with aircraft nuts
or nylocks or #10 screws provide for solid mounting.
ELECTRICAL
DC WIRE CONNECTIONS
Each output should be connected only to a standard 12V lead-acid
battery.
DC wire connections must be made before plugging in the AC
cord. The charger will not operate until DC connections are made.
Do not remove DC connections while the AC cord is plugged in.
When installing in the bilge and or battery compartment of boats,
open hatches and operate bilge blowers if any for ten minutes to
removeany fumesand hydrogen gas.Be certain the area isventilated
for personal health and safety
Keep wire routing from the charger to the battery neat and secure
by anchoring with cable tie to a solid surface every few inches, not
to exceed 18” intervals.
An in-line fuse must be installed to both the positive (red) and the
negative(black) leads to the battery to provide protection if the DC
cord is somehow damaged.
Connect #1 lead set to battery #1, red to positive and black to
negative. Connect lead set #2 to battery #2, red to positive and
black to negative. Do not leave any lead set disconnected when
chargingless than twobatteries. If chargingonly one battery connect
both red leads to positive, and both black leads to negative. If
charging two batteries, connect one of the lead sets to one battery
and the other lead set to the other battery. All connections should
be clean and tight. See installation diagrams.
AC Wire Connections
Note:
The Chargetek TPRO220 is equipped with a factory installed 6’
grounded AC cord. Though hook up is only a matter of plugging
this cord into a suitable extension cord, please follow the following
precautionary tips.
Insure that the AC cord cannot reach moving parts, lids, hoods,
etc. Secure with a cable tie to solid anchor point if necessary.
Thecharger will operate properly with either115 volts 50 Hz or 115
volts 60 HzAC input. Never use 220 volt service with this unit.
CAUTION:
Never connect the AC plug into an electrical outlet when you are
wet or barefoot.
Donotleaveanylead
setdisconnectedwhen
charging less than
twobatteries.
Two Battery
Connection
Single Battery
Connection
SAFETY INSTRUCTIONS
CAUTION: The following are important safety instructions. Save
these instructions.
Charge only lead acid, (maintenance free or refillable), or “gel-cell”
rechargeable batteries. Other types of batteries may burst causing personal
injury and damage
Never smoke or allow sparks or flame in the vicinity of a battery.
Someone should be within range of your voice and close enough to come
to your aid when you are working near a battery.
Wear eye protection and clothing protection. Avoid touching eyes while
working near a battery.
Have plenty of fresh water and soap nearby in case battery acid contact’s
skin, clothing or eyes.
If battery acid contact’s skin or clothing, wash immediately with soap
and water. If acid enters eyes, immediately flood eyes with running cold
water for at least ten minutes and get immediate medical attention.
Never operate a charger with a damaged cord or plug. Wearing ofAC and
DC cords, accidentally nicking or cutting the cords could result in sparking
and cause injury.
Never operate a charger that has been damaged in any way or try to
disassemble. Return to factory when service or replacement is required.
Incorrect reassembly may result in a risk of electrical shock or fire.
Become familiar with all instructions, specifications and cautionary
markings on chargers, batteries and equipment used. Only adults should
install and operate the charger. Children should be kept out of reach of the
charger and batteries it is charging.
When using an extension cord the Chargetek TPRO220 requires a quality
grounded extension cord of at least 16 awg wire size for cords up to 50’
and a minimum of 14 awg for cords up to 150’.
Never unplug a cord by pulling on the cord itself. Always grasp the plug
when disconnecting the charger.
Even though the Chargetek TPRO220 is waterproof and designed for
harsh environments, do not operate submerged.
Never charge a frozen battery. If the battery has an odor or is visibly
damaged disconnect charger and consult factory.
Study battery manufacturer’s precautions such as removing or not
removing cell caps while charging.
Keep batteries full. Add distilled water in each cell until it reaches levels
specified by battery
Keep battery terminals clean.Always unplug charger before cleaning and
be careful to keep corrosion from coming in contact with eyes.
Remove personal metal items such as rings, bracelets, necklaces, and
watches when working with a lead-acid battery. A lead-acid battery can
produce a short circuit high enough to weld a ring, etc. to metal, causing a
severe burn.
THREE STATE CHARGE CYCLE
The TPRO220 employs a three state charge routine. This is the
charging procedure most lead-acid battery manufacturers rec-
ommend to return full capacity efficiently and extend battery
life. Please refer to the figure Three State Charging Curve dia-
gram.
STAGE I: CONSTANT CURRENT CHARGING OR BULK CHARGE MODE
Assuming the battery is starting in a discharged state, the charg-
ing is operating in constant current mode, where the charger
current is maintained at a constant value and the battery voltage
is allowed to rise as it is being recharged. Approximately 80%
of battery capacity is returned in the constant current region.
STAGE II: ABSORPTION MODE
When the battery voltage reaches approximately 2.4 volts per
cell, or 14.6 volts for a 12V battery, the charger voltage is held
constant at this level and the battery current is allowed to re-
duce. This voltage is maintained until the charging current re-
duces substantially indicating a full charge. At this point the
battery is fully charged.
STAGE III: FLOAT MODE
Float mode is the final stage of the charging routine. Float mode
is where the voltage on the battery is maintained at approxi-
mately 2.25 volts per cell, or 13.5 volts for a 12V battery. This
voltage will maintain the full charge condition in the battery
withoutboiling out electrolyteor overchargingthe battery.When
the charger is in this mode all lights on the TRPO220 should be
green.