CTEK D250S Dual User manual

USER MANUAL
CTEK DC/DC BATTERY CHARGER D250S DUAL
AND 12V POWER MANAGEMENT SYSTEM SMARTPASS
FOR ALL TYPES OF LEAD-ACID, WET, MF, AGM and GEL BATTERIES
FULLY AUTOMATIC
2 YEAR WARRANTY
ENDEFRESITNLSEDKNOFI
12V

2
CONGRATULATIONS
on the purchase of your new CTEK professional battery management unit. This unit is part of a
range of professional battery chargers from CTEK SWEDEN AB. It represents the latest technol-
ogy in battery charging. Using the CTEK D250S DUAL and SMARTPASS products, you can
maximize the performance of your 12VDC source.
SAFETY
The unit is designed for 12V lead-acid batteries. Do not use the unit for any other batteries.
Use safety glasses when connecting or disconnecting a battery.
Battery acid is corrosive. Rinse immediately with water if acid comes into contact with skin or
eyes. Seek medical advice.
Make sure that the cables are not being pinched and are not in contact with warm surfaces
or sharp edges.
While charging, a battery can emit explosive gases; avoid sparks in the immediate area.
Always provide for proper ventilation during charging.
Avoid covering the unit.
D250S DUAL is not reverse polarity protected.
Disconnect battery poles before installation
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 230V (shore power), or be attach to
the surface every 300mm.
4. Cables in the engine room must be rated to withstand 70C
D250S DUAL
12V
+OUT
+IN
+IN
Temperature sensor L:2m
Service battery +Alternator battery +
Solar panel + Vehicle ground/Solar panel –
D250S DUAL
The D250S DUAL has 2 inputs. The Service battery will be charged from the alternator, solar
panel, or both in combination. 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:

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




3
EN
DEFINITIONS SOLAR PANEL
Depending on the application, it could also
be referred to as
- PV panel
- Photovoltaic panel
CONNECTIONS
- Solar panel
- Wind power
DEFINITIONS ALTERNATOR BATTERY
Depending on the application, it could also
be referred to as
- Starter battery
CONNECTIONS
- Trailer coupling
- Alternator
- SMARTPASS 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
- SMARTPASS service battery +
D250S DUAL LAMPS
1. Error lamp
2. Power lamp
3. Solar power
lamp
4. Alternator
battery lamp
5. Service bat-
tery lamp
D250S DUAL
12V
+OUT
+IN
+IN
3
45
1
2
Steady lamp
Flashing lamp
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 FUNCTION
D250S DUAL LAMP INDICATION DURING NORMAL OPERATION
D250S DUAL LAMP ERROR INDICATION
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
EXPLANATION RECOMMENDATION
High temperature
detected at either unit
or service 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

4
+IN +OUT
+OUT
SMARTPASS12V
Temperature sensor L:2m
Negative cable connection M8
L:0.3m
Consumers +
Alternator battery + Service battery +
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.

capacity significantly, and lowers the consumer voltage, which increases expected service life of
lights and other electronics.
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battery life. The battery watch also protects navigation, radio and emergency light from being
out of electricity.
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reduce battery life.

s (shore power)
the AC/DC charger needed.
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
1. Error lamp
2. Power lamp
3. Service bat-
tery charging
lamp
4. Alternator
battery
consumption
lamp
5. Alternator
battery charg-
ing lamp
6. Service bat-
tery consump-
tion lamp
+IN +OUT
+OUT
SMARTPASS12V
4
5
3
6
The CTEK SMARTPASS is designed to work together with 1-2 CTEK D250S DUAL, but can also
be used alone.
1
2

5
EN
SMARTPASS LAMP INDICATION DURING NORMAL OPERATION
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
SMARTPASS LAMP FUNCTION
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
+IN +OUT
+OUT
SMARTPASS12V
21 4 3
SMARTPASS LAMP ERROR INDICATION
2 1 4 3 EXPLANATION RECOMMENDATION
Service battery overheated Check condition
and/or installation
Too high current through or temperature at internal relay. Too high
Service battery charge current.
Check service battery. Reduce alternator size or add one more D250S
DUAL in parallel. Service battery 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

6
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 surface 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. Use tool – hand power
without tools is not enough.
INSTALLATION OF CABLES
Figure 1
Figure 2
2Nm
7Nm
Allen key
DRILL TEMPLATE
90,6mm
120mm
210,6mm
25
R,4
168mm

7
EN
SOLAR PANEL SMALL SERVICE BATTERY
INSTALLATION SHEET 1 INSTALLATION SHEET 2
SITUATION
Solar panel
PROBLEM
A solar panel with 36 cells
produces maximum power at
about 17V. 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

SITUATION

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
3. Caravan/trailer: For
13-pole contact, connect
D250S DUAL alternator
battery + to pin #9. Connect
pin #13 to D250S DUAL
vehicle ground –.
D250S DUAL
12V
+OUT
+IN
+IN
D250S DUAL
12V
+OUT
+IN
+IN
WARNING!
•Max 22V input
•Do not connect two solar
panels in series
WARNING!
- Max 22V input

8
SOLAR PANELLARGE BATTERY BANK
INSTALLATION SHEET 3 INSTALLATION SHEET 4
SITUATION

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 guarantees
trouble-free engine starts. The
Starter battery will be pulse
maintained directly from the
Solar panel.
TIP 3
Mount the temperature sensor
on the Starter battery.
SITUATION

panel 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.
The Solar panel is difficult
to synchronize with the
alternator. Due to these issues,
the battery will underperform
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.
D250S DUAL
12V
+OUT
+IN
+IN
D250S DUAL
12V
+OUT
+IN
+IN
WARNING!
- Max 22V input
WARNING!
•Max 22V input
•Do not connect two solar
panels in series

9
EN
12V
RECOND
RECOND
NIGHT
NORMAL
MODE
LARGE SERVICE BATTERY CONNECTING AC/DC CHARGERS
INSTALLATION SHEET 5 INSTALLATION SHEET 6
SITUATION

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
alternator current is used.
The Solar panel is difficult
to synchronize with the
alternator. Due to these issues,
the battery will underperform
and die prematurely.
SOLUTION
The SMARTPASS separates
the two battery 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.
SITUATION
230/110V charger for the
Service and Starter battery
PROBLEM
The 230/110V charger
should charge both the Service
and the Starter battery, 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
the SMARTPASS, going
backwards. The solar panel
will also charge the Starter
battery backwards through the
SMARTPASS
TIP 6
See Tip 1, Tip 2, Tip 4 and
Tip 5
The battery cables of the
230/110V charger are
connected directly to the
Service battery.
D250S DUAL
12V
+OUT
+IN
+IN
+IN +OUT
+OUT
SMARTPASS12V
D250S DUAL
12V
+OUT
+IN
+IN
+IN +OUT
+OUT
SMARTPASS12V
WARNING!
•Max 22V input
•Do not connect two solar
panels in series
WARNING!
•Max 22V input
•Do not connect two solar
panels in series

10
CONNECTING CONSUMERS
INSTALLATION SHEET 7
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

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
(>80A) should be connected
directly to the Service or
Starter battery
12V
RECOND
RECOND
NIGHT
NORMAL
MODE
D250S DUAL
12V
+OUT
+IN
+IN
+IN +OUT
+OUT
SMARTPASS12V
WARNING!
•Max 22V input
•Do not connect two solar
panels in series

11
EN
STEP 1 DESULPHATION
Detects sulphated batteries. Pulsing current and voltage, removes sulphate from the lead plates
of the battery restoring battery capacity.
STEP 2 BULK
Charging with maximum current until approximately 80% battery capacity.
STEP 3 ABSORPTION
Charging with declining current to maximize up to 100% battery capacity.
STEP 4 FLOAT
Maintaining the battery voltage at maximum level by providing a constant voltage charge.
STEP 5 PULSE
Maintaining the battery at 95–100% capacity. The charger monitors the battery voltage and
gives a pulse when necessary to keep the battery fully charged.
1
VOLTAGE (V)CURRENT (A)
PULSE
DESULPHATION BULK ABSORPTION
14 2 3
FLOAT
5
CHARGING PROGRAM D250S DUAL
The charger starts charging the target battery when the supply voltage exceeds 13.1V for 5 sec (engine on).
The charger stops charging the target battery when the supply voltage drops below 12.8V for 10 sec (engine off).
*Supply program is not time or voltage limited.

12
TECHNICAL SPECIFICATIONS
Charger model D250S DUAL SMARTPASS
Model number 1027 1058
Max input voltage 22V 22V
Charging voltage 14.4V at 25°C, temperature
compensated
-
Charging current 20A 80A
Back current drain <1Ah/month <1Ah/month
Ripple* <4%
Ambient
temperature
-20°C to +50°C, output power is reduced automatically at high
temperatures
Charger type 5-step fully automatic charging
Battery types All types of 12V lead-acid batteries (WET, MF, Ca/Ca, AGM and GEL)
Battery capacity 40-300Ah 75-800Ah
Dimensions 197 x 93 x 49mm (L x W x H)
Insulation class IP65 (splash and dust proof)
Weight 0.73kg 0.74kg
MPPT** Yes -
*) The quality of the charging voltage and charging current are very important. High current
ripple heats the battery and ages the positive electrode. High voltage ripple can damage
other equipment connected to batteries. The battery chargers from CTEK produce very high-
quality voltage and current with low ripple
**) MPPT (Maximum Power Point Tracking) nds the best combination of supply current and
voltage to maximize the power output. This is especially important for Photovoltaic (Solar)
Panels and trailer campers with wiring constraints.
CABLE DIMENSIONS
Recommended minimum cable dimensions in mm²
MIN CABLE DIMENSIONS
UNIT CABLE 0.5m 1m 2m 5m 10m
+IN 4mm24mm24mm26mm210mm2
+OUT 4mm26mm210mm2
Lead to ground 1.5mm21.5mm21.5mm21.5mm21.5mm2
Connection Unit* 4mm26mm210mm210mm210mm2
+IN 10mm216mm216mm225mm225mm2
+OUT 10mm216mm216mm2
*Use included connectors if possible. The cable dimensions are if the units are mounted at dierent locations.
D250S/D250S DUAL
SMARTPASS

13
EN
SUPPORT
CTEK offers professional custom support: www.ctek.com. For the latest revised user manual,
see www.ctek.com. By e-mail: [e-mail], by telephone: [phone], by fax: +46
225 351 95. By mail: CTEK SWEDEN AB, Rostugnsvägen 3, SE-776 70 VIKMANSHYTTAN,
SWEDEN.
VIKMANSHYTTAN, SWEDEN 2010-06-15
Jarl Uggla, President
CTEK SWEDEN AB
LIMITED WARRANTY
CTEK SWEDEN AB, issues this limited warranty to the original purchaser of this product. This
limited warranty is not transferable. The warranty applies to manufacturing faults and material
defects for 2 years from the date of purchase. The customer must return the product together
with the purchase receipt. This warranty is void if the battery charger has been opened,
handled carelessly or repaired by anyone other than CTEK SWEDEN AB or its authorised

damaging the seal will void the warranty. CTEK SWEDEN AB makes no warranty other than this
limited warranty and is not liable for any costs other than those mentioned above. For example,
consequential damages are not covered. Moreover, CTEK SWEDEN AB is not obligated to any
other warranty other than this warranty.
CTEK PRODUCTS ARE PROTECTED BY
Patents Designs Trade marks
EP1618643 RCD 000509617 CTM TMA669987
SE525604 US D571179 CTM 844303
US7541778B2 US D575225 CTM 372715
EP1744432 pending US D581356 CTM 3151800
EP1483817 pending US D580853 CTM 405811
SE524203 RCD 321216 CTM 1461716 pending
US7005832B2 RCD 200830199948X pending
EP1716626 pending RCD 000911839
SE526631 RCD 081418
US-2006-0009160-A1 pending US D29/319135 pending
EP1903658 pending RCD 001119911
EP1483818 RCD 321197
US7629774 RCD 321198
SE528232 RCD 200830120183.6 pending
EP09170640.8 pending ZL200830120184.0
US12/564360 pending RCD 000835541
EP09180286.8 pending US D596125
US12/646405 pending US D596126
2010-01-27
TEMPERATURE PROTECTION
SMARTPASS has a temperature sensor cable. The units will automatically protect
the service battery if the temperature and charging voltage together are too high.
Charging will then only be performed by the D250S battery charger. The temperature
should be measured close to the battery, therefore attach the sensor to the battery.

CTEK SWEDEN AB
