CTEK D250S Dual User manual

EN
EN • 3
CONGRATULATIONS
on the purchase of your new CTEK professional battery man-
agement unit. This unit is part of a range of professional bat-
tery chargers from CTEK SWEDEN AB. It represents the latest
technology in battery charging.
Using the CTEK D250S DUAL and SMARTPASS products, you
can maximize the performance of your 12V DC source.
IMPORTANT SAFETY
INSTRUCTIONS
CALIFORNIA PROPOSITION 65
WARNING: This product contains chemical known to the state
of California to cause cancer or reproductive toxicity.
1. SAVE THESE INSTRUCTIONS
– This manual contains important safety and operating
instructions for battery charger Models D250S DUAL
(1044) and SMARTPASS (1058).
2. Use of an attachement not recommended or sold by the
CTEK may result in a risk of fire, electric shock, or injury to
persons.
3. When charging, batteries can emit explosive gases,
therefore it is essential to prevent flames and sparks. The
charger is designed for charging 12V lead-acid batteries.
Do not use for any other purpose.
4. Always provide good ventilation when charging.
5. Make sure that cables used have sufficient cable area,
see CABLE DIMENSIONS.
6. Do not operate charger with damaged cord - replace the
cord immediately.
7. Never operate the charger if it has received a sharp blow,
been dropped or otherwise damaged in any way; take it
to a CTEK representative.
8. Do not disassemble charger; take it to the retailer when
service or repair is required. Incorrect reassembly may
result in a risk of electrical shock or fire.
9. Disconnect the products before attempting any mainte-
nance or cleaning
10. WARNING - RISK OF
EXPLOSIVE GASES
a) WORKING IN VICINITY OF
A LEAD-ACID BATTERY IS
DANGEROUS. BATTERIES
MANUAL
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4 • EN
GENERATE EXPLOSIVE GASES
DURING NORMAL BATTERY
OPERATION. FOR THIS
REASON, IT IS OF UTMOST
IMPORTANCE THAT, YOU
FOLLOW THE INSTRUCTIONS
EACH TIME YOU INSTALL THE
CHARGER.
b) To reduce risk of battery explosion, follow these instruc-
tions and those published by the battery manufacturer
and the manufacturer of any equipment you intend to use
in vicinity of battery. Review cautionary marking on these
products and on engine.
c) Disconnect battery poles before installation
d) D250S DUAL is not reverse polarity protected.
11. PERSONAL PRECAUTIONS
a) Consider having someone close enough by to come to
your aid when you work near a lead-acid battery.
b) Have plenty of fresh water and soap nearby in case bat-
tery acid contacts skin, clothing or eyes.
c) Wear complete eye protection and clothing protection.
Avoid touching eyes while working near battery.
d) If battery acid contacts skin or clothing, wash immediately
with soap and water. If acid enters eye, immediately flood
eye with running cold water for at least 10 minutes and
get medical attention immediately.
e) NEVER smoke or allow a spark or flame in vicinity of bat-
tery or engine.
f) Be extra cautious to reduce risk of dropping a metal tool
onto battery. It might spark or short-circuit battery or other
electrical part that may cause explosion.
g) Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with lead-acid
battery. A lead-acid battery can produce a short-circuit
current high enough to weld a ring or the like to metal,
causing a severe burn.
h) Use charger for charging a LEAD-ACID battery only. Do
not use battery charger for charging dry-cell batteries that
are commonly used with home appliances. These batter-
ies may burst and cause injury to persons and damage to
property.
i) Never charge a frozen battery.
12. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge,
always remove grounded terminal from battery first. Make
sure all accessories in the vehicle are off, so as not to
cause an arc.
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b) Be sure area around battery is well ventilated while bat-
tery is being charged.
c) Clean battery terminals. Be careful to keep corrosion from
coming in contact with eyes.
d) Add distilled water in each cell until battery acid reaches
level specified by battery manufacturer. Do not overfill.
For a battery without removable cell caps, such as valve
regulated lead acid batteries, carefully follow manufac-
turer’s recharging instruction.
e) Study all battery manufacturer’s specific precautions while
charging and recommended rates of charge.
f) Determine voltage of battery by referring to vehicles
manual.
13. CHARGER LOCATION
a) Never place charger directly above battery being
charged; gases from battery will corrode and damage
charger.
b) Never allow battery acid to drip on charger when read-
ing electrolyte specific gravity or filling battery.
c) Do not set a battery on top of charger.
14. FOLLOW THESE STEPS WHEN
BATTERY IS INSTALLED IN
VEHICLE. A SPARK NEAR
BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK
OF A SPARK NEAR BATTERY:
a) Position cords to reduce risk of damage by hood, door or
moving engine part.
b) Stay clear of fan blades, belts, pulleys, and other parts
that can cause injury to persons.
c) Check polarity of battery posts. POSITIVE (POS, P, +)
battery post usually has larger diameter than NEGATIVE
(NEG, N, -) post.
d) Determine which post of battery is grounded (connected)
to the chassis. If negative post is grounded to the chassis
(as in most vehicles) see (e). The battery charger can
not be used with positive-grounded batteries.
e) For Negative-grounded vehicle, connect POSITIVE con-
nector from battery charger to POSITIVE (POS, P, +)
ungrounded post of battery. Connect NEGATIVE connec-
tor from battery charger to vehicle chassis or engine block
away from battery. Do not connect to carburetor, fuel
lines, or sheet-metal body parts. Connect to a heavy gage
metal part of the frame or engine block.
f) When disconnecting charger, always do so in reverse
sequence of connecting procedure and break first connec-
tion while as far away from battery as practical.
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6 • EN
15. FOLLOW THESE STEPS WHEN
BATTERY IS OUTSIDE VEHICLE.
A SPARK NEAR BATTERY MAY
CAUSE BATTERY EXPLOSION.
TO REDUCE RISK OF
A SPARK NEAR BATTERY:
a) Check polarity of battery terminals. POSITIVE (POS,
P, +) battery post usually has a larger diameter than
NEGATIVE (NEG, N, -) post.
b) Attach at least a 24-inch-long 6-gauge (AWG) insulated
battery cable to NEGATIVE (NEG, N, —) battery post.
c) Connect POSITIVE charger connector to POSITIVE (POS,
P, +) post of battery.
d) Position yourself and free end of cable as far away from
battery as possible – then connect NEGATIVE charger
connector to NEGATIVE (NEG, N, -) post of battery.
e) Do not face battery when making the final connection.
f) When disconnecting charger, always do so in reverse
sequence of connecting procedure and break first connec-
tion while as far away from battery as practical.
SAFETY
•D250S Dual and SMARTPASS is designed for 12V lead-
acid batteries. Do not use the unit for any other batteries.
•Disconnect battery poles before installation
•D250S Dual is not sprak proof.
•The installation must include a fuse according to recommen-
dations in table “CABLE DIMENSIONS”.
All installations on boats must follow
ISO 10133. Please note!
1. Connections from the battery must be fused close to the
battery.
2. Batteries must be permanently mounted in ventilated areas.
3. Cables must be placed in tubes, separated from cables for
110/230V (shore power), or be attach to the surface every
300mm.
4. Cables in the engine room must be rated to withstand
70°C/158°F
5. For a permanently connencet battery charger:
GROUNDING INSTRUCTIONS— This battery charger
should be connected to a grounded, metal, permanent
WARNING!
D250S DUAL and SMARTPASS is not
reverse polarity protected.
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wiring system; or an equipment-grounded conductor should
be run with circuit conductors and connected to equipment-
grounded terminal or lead on battery charger. Connections
to battery charger should comply with all local codes and
ordinances.
D250S DUAL
The D250S Dual has 2 inputs. The Service battery will be
charged from the alternator, solar panel, or both in combina-
tion. The solar panel adjusts itself to the Starter battery voltage.
The Starter battery will be charged and maintained directly by
the solar panel if the Service battery is fully charged.
D250S DUAL
FEATURES:
•Multi-step 20A temperature compensated battery charging
and battery maintenance.
•Battery separation of Starter and Service batteries.
•Maximum power point tracking for solar panels charging
the Service battery.
•Two power source inputs (alternator, solar, wind, Supply
battery and other).
•Coordination of the two inputs, allowing parallel operation.
•The solar input will also maintain the Alternator battery.
•Built in battery guard for the Alternator battery.
D250S DUAL
12V
+OUT
+IN
+IN
Temperature sensor
L:2m/6,5 feet
Service
battery +
Alternator
battery +
Solar panel + Vehicle ground/
Solar panel –
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DEFINITIONS SOLAR PANEL
Depending on the application, it could also be referred to as
- PV panel
- Photovoltaic panel
CONNECTIONS
- Solar panel
- Wind power
DEFINITIONS SERVICE BATTERY
Depending on the application, it could also be referred to as
- House battery
- Domestic battery
- Consumer battery
CONNECTIONS
- Electrical equipment
- Battery bank
- SMARTPASS service battery +
DEFINITIONS ALTERNATOR BATTERY
Depending on the application, it could also be referred to as
- Starter battery
CONNECTIONS
- Trailer coupling
- Alternator
- SMARTPASS Alternator +
D250S DUAL LAMPS
D250S DUAL
12V
+OUT
+IN
+IN
Error lamp
Power lamp
Solar power
lamp
Alternator
battery lamp
Service
battery lamp
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D250S DUAL LAMP ERROR INDICATION
EXPLANATION RECOMMENDATION
High temperature detected at either unit or ser-
vice battery Consider relocationg unit and/or service battery
Service battery connection problem detected Check Service battery connection and fuse
Service battery connection problem detected Check Service battery connection and fuse
Service battery connection problem detected Check Service battery connection and fuse
Steady lamp Flashing lamp
D250S DUAL LAMP FUNCTION
LAMP FUNCTION
Power lamp D250S DUAL connected
correctly, ready to use
Alternator battery lamp Alternator running
Service battery lamp Charging of Service
battery
Solar panel lamp Solar panel in operation
D250S DUAL LAMP INDICATION
DURING NORMAL OPERATION
LIT WITH A STEADY GLOW
Service battery charged by the
alternator
Service battery charged by the solar
panel
Service battery charged by both the
alternator and solar panel
Service battery fully charged.
Alternator battery maintained by the
solar panel
When the Power lamp flickers, the unit
is in power saving mode
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SMARTPASS
SMARTPASS can operate as a stand-alone unit, but works best
in combination with D250S Dual. The SMARTPASS creates
a priority path for charging the Service battery to recharge
it more quickly and efficiently. Attached energy sources like
solar, wind or shore power will charge both the Service and
the Starter batteries through the SMARTPASS. Service batteries
that are overheated due to age, high ambient temperature or
other battery problems will be protected from high alternator
current.
SMARTPASS
FEATURES:
The CTEK SMARTPASS adds additional functionality for higher
output alternators, larger battery banks and/or high parallel
loads.
•Separation of consumers and Service batteries during
charging, which improves the charging capacity signifi-
cantly, and lowers the consumer voltage, which increases
expected service life of lights and other electronics.
•Service battery watch, which avoids harmful deep dis-
charges that otherwise would shorten battery life. The bat-
tery watch also protects navigation, radio and emergency
light from being out of electricity.
•Over-temperature protection of Service battery. High bat-
tery temperature could significantly reduce battery life.
•Maintenance charge of Starter battery, which simplifies
installation with fewer components.
•Simplified installation of AC/DC chargers (shore power).
Only one output from the AC/DC charger needed.
The CTEK SMARTPASS is designed to work together with
1-2 CTEK D250S DUAL, but can also be used alone.
+IN +OUT
+OUT
SMARTPASS12V
Temperature sensor
L: 2m/6.5 feet
Negative cable
connection M8
L: 0.3m/12 inches
Consumers +
Alternator
battery + Service battery +
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DEFINITIONS ALTERNATOR BATTERY
Depending on the application, it could also be referred to
as
- Starter battery
CONNECTIONS
- Trailer coupling
- Solar panel
- Wind power
- Alternator
- D250S DUAL Alternator battery +
DEFINITIONS SERVICE BATTERY
Depending on the application, it could also be referred to
as
- House battery
- Domestic battery
- Consumer battery
CONNECTIONS
- Electrical equipment
- Battery bank
- D250S DUAL Service battery +
DEFINITIONS CONSUMERS
Depending on the application, it could also be referred to
as
- Electrical equipment +
CONNECTIONS
- Electrical equipment
SMARTPASS LAMPS
SMARTPASS12V
+OUT
+OUT
+IN
2
3
1
4
Error lamp
Power lamp
1. Service battery
charging lamp
2. Alternator battery con-
sumption lamp
3. Alternator battery
charging lamp
4. Service battery
consumption lamp
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12 • EN
SMARTPASS LAMP FUNCTION
LAMP STEADY FLASHING
Power lamp Unit ready to use
2Alternator battery
consumption lamp Engine running Too high current through relay
1Service battery
charging lamp Charging Service battery
4Service battery
consumption lamp Consumers powered by Service battery Too high current through relay
3Alternator battery
charging lamp Alternator battery maintained by Service battery Too high current through relay
Error lamp Indicates that an error has occurred. See the
table to the right.
SMARTPASS LAMP INDICATION DURING NORMAL OPERATION
EXPLANATION
High current from alternator to service battery. Consumer powered by alternator
Reduced current from alternator to service battery. Consumer powered by alternator
Consumer powered by alternator. Battery charged by D250S DUAL charger
Pulse maintenance of starter battery
21 4 3
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SMARTPASS LAMP ERROR INDICATION
2143 EXPLANATION RECOMMENDATION
Service battery overheated Check condition and/or installation
Too high current through or temperature
at internal relay. Too high Service bat-
tery charge current.
Check service battery. Reduce alternator size or
add one more D250S DUAL in parallel. Service bat-
tery bank too deeply discharged.
Too high current through or temperature
at internal relay. Too many consumers
connected at the same time.
Consider relocation of unit. Reduce power usage.
Too high current through or temperature
at internal relay. Too high current to
starter battery.
Starter battery problems, check battery.
Too high current through or temperature
at internal relay. Too many consumers
connected.
Relocate unit or reduce concurrent use of consumers.
Battery watch activated. Service battery
too low Recharge Service battery
Steady lamp Flashing lamp
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INSTALLATION OF UNIT
1. Attach the temperature sensor holder on a flat surface on
one Service battery. Position it as close as possible to a
positive post.
2. Use the included drill template. Wiring is simplified if the
units are installed according to the drill template, but other
setups are possible.
3. Install the unit(s) on a surface where it can be properly
fixed and where the unit is not exposed to fuels, oils or
splashes of dirt.
4. Mount the unit with screws intended for the surface and
attach it with one screw in each of the four holes in the
corners of the unit. See picture 1. Mount the unit with M4
or ST4.2 screws. The required torque depends on the sur-
face for mounting. Fig. 1 shows a CTEK D250S. The same
procedure is used for all devices.
5. Attach the cables and mount the cable screws with a
torque of 7 Nm/62 Lb-In. Use tool – hand power without
tools is not enough.
6. The ground cable of the SMARTPASS should be connect-
ed to the ground screw of the DUAL or to any convinient
ground connection point.
INSTALLATION OF CABLES
Figure 1
Figure 2
2Nm/18 Lb-In
7Nm/62 Lb-In
Allen key
WARNING!
D250S DUAL and
SMARTPASS is not reverse
polarity protected.
Disconnect battery poles
before installation.
WARNING!
D250S DUAL is not spark
proof. Provide for good
ventilation.
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DRILL TEMPLATE
90,6mm/3,57 inches
120mm/4,72 inches
210,6mm/8,29 inches
Ø4,9 mm
0,19 inches
168mm/6⅝ inches
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16 • EN
SITUATION
Solar panel.
PROBLEM
A solar panel with 36 cells produces
maximum power at about 17V. Many
regulator reduce the voltage by “burning
off” energy.
SOLUTION
The D250S DUAL searches for the
Maximum Power Point and charges
the battery perfectly with very high
efficiency.
TIP 1
Mount the temperature sensor on the
Service battery.
Boat: All installation should be done in
accordance with ISO10133.
INSTALLATION SHEET 1
WARNING!
•Max23Vinput
•Donotconnecttwosolarpanelsinseries
WARNING!
D250S DUAL is not reverse
polarity protected
SOLAR PANEL
D250S DUAL
12V
+OUT
+IN
+IN
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WARNING!
Max 23V input
WARNING!
D250S DUAL is not reverse
polarity protected
SITUATION
One alternator feeding a Starter battery
and a small Service battery.
PROBLEM
The Service battery will take a very long
time to recharge due to low alternator
voltage. Due to this, the battery will
underperform and die prematurely.
SOLUTION
The D250S DUAL charges the Service
battery quickly and very efficiently. The
battery will be fully charged, produce
more and last significantly longer.
TIP 2
Refer to Tip 1.
Alternators with voltage sensor cables
should connect this on the Starter battery
Caravan/trailer: For 13-pole contact,
connect D250S DUAL alternator battery
+ to pin #9. Connect pin #13 to D250S
DUAL vehicle ground –.
INSTALLATION SHEET 2
SMALL SERVICE BATTERY
D250S DUAL
12V
+OUT
+IN
+IN
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18 • EN
SITUATION
One alternator feeding a Starter battery
and a large Service battery bank.
PROBLEM
The Starter battery will not be fully
charged and might not always be able
to start the engine.
SOLUTION
The D250S DUAL recharges the Starter
battery quickly to 100%, which guaran-
tees trouble-free engine starts.
TIP 3
Mount the temperature sensor on the
Starter battery.
INSTALLATION SHEET 3
LARGE BATTERY BANK
WARNING!
Max 23V input
WARNING!
D250S DUAL is not reverse
polarity protected
D250S DUAL
12V
+OUT
+IN
+IN
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EN
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SITUATION
One alternator and a Solar panel feed-
ing a Starter battery and a small Service
battery.
PROBLEM
The Service battery will take a very long
time to recharge due to low alternator
voltage. The Solar panel is difficult to
synchronize with the alternator. Due to
these issues, the battery will underper-
form and die prematurely.
SOLUTION
The D250S Dual charges the Service
battery quickly and very efficiently
from both the Alternator and the Solar
panel. The Solar panel produces at its
maximum power point when the engine
is off. When both the Solar panel and
the Alternator are on, the Solar panel
adjusts to the Alternator. The battery will
be fully charged, produce more and last
significantly longer.
TIP 4
See Tip 1 and Tip 2.
INSTALLATION SHEET 4
SOLAR PANEL
WARNING!
D250S DUAL is not reverse
polarity protected
WARNING!
•Max23Vinput
•Donotconnecttwosolarpanelsinseries
D250S DUAL
12V
+OUT
+IN
+IN
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20 • EN
LARGE SERVICE BATTERY
INSTALLATION SHEET 5
D250S DUAL
12V
+OUT
+IN
+IN
+IN +OUT
+OUT
SMARTPASS12V
SITUATION
One alternator feeding a Starter battery
and a large Service battery.
PROBLEM
The Service battery will take a very long
time to recharge due to low alternator
voltage and restrictions in how the alter-
nator current is used. The Solar panel is
difficult to synchronize with the alterna-
tor. Due to these issues, the battery will
underperform and die prematurely.
SOLUTION
The SMARTPASS separates the two bat-
tery banks when the engine is off. With
the engine on, the alternator charges
the service battery with its maximum
current until it has tapered off to the
D250S Dual max level. Then the D250S
DUAL charger finalizes the charge. The
recharge time is minimized. Solar panels
are easily integrated and synchronized if
a D250S Dual is used together with the
SMARTPASS.
TIP 5
See Tip 1, Tip 2 and Tip 4
Wires that are connected to both
SMARTPASS and D250S DUAL should
be connected to SMARTPASS.
WARNING!
•Max23Vinput
•Donotconnecttwosolarpanelsinseries
WARNING!
D250S DUAL and SMARTPASS is not
reverse polarity protected
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EN
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SITUATION
230/110V charger for the Service and
Starter battery.
PROBLEM
The 230/110V charger should charge
both the Service and the Starter bat-
tery, and be synchronized with all other
energy sources.
SOLUTION
The single output 230/110V charger is
connected directly to the Service battery.
The Starter battery is pulse charged
through SMARTPASS.
The solar panel will also maintaince
charge the Starter battery through
SMARTPASS.
TIP 6
See Tip 1, Tip 2, Tip 4 and Tip 5
The battery cables of the 230/110V
charger are connected directly to the
Service battery.
INSTALLATION SHEET 6
CONNECTING AC/DC CHARGERS
WARNING!
•Max23Vinput
•Donotconnecttwosolarpanelsinseries
WARNING!
D250S DUAL and SMARTPASS is not
reverse polarity protected
12V
RECOND
RECOND
NIGHT
NORMAL
MODE
D250S DUAL
12V
+OUT
+IN
+IN
+IN +OUT
+OUT
SMARTPASS12V
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22 • EN
CONNECTING CONSUMERS
SITUATION
Connection of consumers to the system.
PROBLEM
Many batteries die prematurely if they
are discharged too much. Too little
power might be delivered to critical
consumers, like navigation, radio and
emergency lights.
SOLUTION
Critical consumers are connected
directly to the battery. Others, such as
refrigerator, main light and heating are
connected to the SMARTPASS. When
the Service battery is down to a critical
level, then the SMARTPASS disconnects
these noncritical consumers.
TIP 7
See Tip 1, Tip 2, Tip 4, Tip 5 and Tip 6.
High current consumers (>80A) should
be connected directly to the Service or
Starter battery.
WARNING!
•Max23Vinput
•Donotconnecttwosolarpanelsinseries
WARNING!
D250S DUAL and SMARTPASS is not
reverse polarity protected
12V
RECOND
RECOND
NIGHT
NORMAL
MODE
D250S DUAL
12V
+OUT
+IN
+IN
+IN +OUT
+OUT
SMARTPASS12V
INSTALLATION SHEET 7
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