Fullwat FUM-2410CBP User manual

User’s manual
- 1 -
FUM – 2410/15/20CBP
FUM-2410CBP / FUM-2415CBP / FUM-2420CBP
3 stage battery charger
User’s manual
Keep this manual in a safe place for quick reference at all times.
This manual contains important safety and operationinstructions for correct use of the battery charger. Read through the manual and
pay special attention to the markings and labels of the charger, battery and equipment connected to the battery system.
Pay special attention to these two types of notices used in this manual.
WARNING
Failure to heed this warning may cause injury to persons and damage to equipment.
CAUTION
Failure to observe this warning may result in damage to equipment and improper functioning of the charger.
WARNING
•The charger is designed for in-door use. Protect the charger from ingress of water.
•This charger is made to charge only properly sized lead acid batteries.
•Charging other types of battery or under-sized lead acid batteries may cause fire or explosion.
•Install the charger in accordance with all local codes.
•Do not use the charger if it has been dropped or damaged.
•Do not remove casing of the charger, there is no user-serviceable parts inside.
•Do not charge the battery on boats. Remove the battery and charge on shore.
•Never attempt to charge a frozen battery.
•Never attempt to charge a damaged battery.
•Wear protective goggles and turn your face away when connecting or disconnecting the battery.
•Never place the charger on top of a battery.
•Never smoke, use an open flame, or create sparks near battery or charger during normal charging operation as batteries may
giveout explosive gas.
•Do not charge batteries in an enclosure (box-in) due to possible explosion of entrapped explosive gas.
•Use of accessory not recommended may cause risk of fire, electric shock.
•Disconnect the mains supply before connecting or disconnecting the links to the battery.
•If the charger does not work properly or if it has been damaged, unplug its AC and DC connection.
CAUTIONS
•Refer to battery manufacturer’s specific recommended values for battery type settings and float voltage setting.
•Fix the charger to a stable surface using the holes at the flange.
•Ensure all ventilation ports are not obstructed for efficient fan cooling, keep loose soft material or paper off at the bottomofthe
charger.
•If longer output charging cord is required, make sure the diameter is adequate for the current in given cable length.

User’s manual
- 2 -
FUM – 2410/15/20CBP
Introduction
Congratulations on purchasing our new 3-Stage (IUoU) switching mode battery charger.
This battery charger is suitable for wet, sealed (RVLA), calcium-calcium, gelandAGMinbothcar(SLI)anddeepcycletypeof
lead acid battery.
It is a “set and forget” automatic charger which can be permanently connected to battery.
These models have dual charge banks for charging two batteries simultaneously.
The special selectable Power Supply mode allows charging battery with external load.
Intended use:
All automotive, marine, mobile ho me, electric scooters, golf carts, solar, deep cycle, UPS standby, industrial & comercial
applications.
A. Control and indicators
1. Battery charger / power supply selection
Slide switch to set charger to 3 stage charger or po w e r supply mode (See section G)
2. Battery type selection
Slide switch to set charger for AGM/gel, wet and calcium-calcium type battery.
3. Float voltage selection
Slide switch to set float charge voltage to 26.4 / 27.0V / 27.6V.
4. Charge status LED display
Charger ON LED
: Green - 3 stage charger mode. // Red - Power supply mode.
BULK LED(Red)
: Bulk charging with constant max. current.
ABSORPTION LED (Orange)
: Absorption charging with preset constant max. voltage.
FLOAT LED (Green)
: Float charging with preset constant voltage.
5. FAULT LED (Red)
Charger malfunction (See trouble shooting)
6. Car blade fuse
Thermal fuse for reverse polarity protection.
7. Charging banks
S c r e w terminals to connect to supplied charging cable.
8. Temperature sensor socket
Connection to optional accessory ATS-5120.
Sensor to increase / decrease charge voltage at low / high battery temperature.
9. Remote control socket
Connection to optional accesory ABD-4120.
To remote display the charging voltaje & charging status and remote control the charger output ON/OFF.
Fig.1

User’s manual
- 3 -
FUM – 2410/15/20CBP
10. Power switch
To turn on and off AC power to charger.
11. Inlet AC socket wirh fuse holder
B. Battery type selection
AGM/GEL : Sealed type (VRLA), AGM-GEL, maintenance free, automotive or deep cycle lead acid batteries.
Wet : Flooded type lead acid batteries (to which water can be added) automotive or deep cycle.
Calcium-Calcium : Sealed type (VRLA) lead acid batteries with calcium content automotive or deep cycle.
B1. Float voltage selection
These fine tuned selections of float voltages enable the best voltage level for maximum battery life. Choose 13.8V when in doubt
or in po w e r supply mode.
Follow the markings on deep cycle batteries of the standby float voltage.
B2. Recommended battery capacity
The following minimum Ah capacities are a generalized suggestion, some batteries can take higher charge current, check with
battery manufacturers for charging batteries with smaller capacity.
Charger model
FUM – 2415CBP, 15A
FUM – 2420CBP, 20A
FUM – 2425CBP, 25A
Battery capacity
50 Ah ~ 150 Ah
70 Ah ~ 200 Ah
80 Ah ~ 250 Ah
C. Battery charger installation and connection
Observe the warnings & safety precautions before rushing to install and operate the charger.
Check battery condition, fill up cells for wet battery, clean battery poles.
Secure the battery charger in a well ventilated place, make sure the mounting surface is flat and without soft covering material or
loose paper sheet. The air intake is at the bottom and air outlet at the back. Make sure both intake and outlet are not blocked.
Never place charger on top of battery.
Plug in the AC mains and turn on po w e r switch, the charger ON LED and the float LED should be on green indicating charger is
in good order for charging lead acid battery.
Before connecting or disconnecting the charging cable, turn off the po w e r switch and unplug AC cord from the mains. First
connect the red cable to positive + terminal of charger and the battery positive + pole. Then connect the black cable to the negative
– terminal and the negative – pole of the battery.
Make sure all the connections are secured and well tighten up, double check on the correct polarity.
Double check again for correct selection of slide switch 1 at charger mode, switch 2 for battery type and switch 3 for float voltage
setting value.
Fig.2

User’s manual
- 4 -
FUM – 2410/15/20CBP
D. Normal 3 stage (IUoU) charging operation
The 3 stage IUoU charge algorithm ensures fast, complete and at the same time gentle charging of the lead acid battery.
Stage 1. THE I-PHASE. The constant current charging, bulk LED is on.
Normally the battery is charged at constant maximum current until it rises to the selected absorption voltage level.
The charging voltage changes with the battery voltage.
If the initial battery voltage is less than 18V due to deep discharge, the bulk charge current is reduced to half of the maximum until
battery voltage rises over 18V.
Stage 2. THE Uo-PHASE. The constant voltage charging, absorption LED is on.
Battery type selection: Gel: 28.2V // AGM: 28.6V // Wet: 28.8V // Calcium: 31.1V
When the battery voltage rises to the selected absorption voltage level, the charging switches to constant voltage charging and
battery is over 85% full. The battery is kept at this high voltage while the current reduces gradually to set value at which the
charger automatically switches to float stage.
Stage 3. THE U-PHASE. The constant voltage charging, float LED is on.
Float voltage selection: 26.4 V // 27.0V // 27.6V
In this stage, the battery is full and only takes in the amount of current necessary for maintaining the capacity. The float voltage is
preset independently by user according to the type of battery such that battery can be connected permanently to the charger when
it is not in use.
E. Manual equalization charging for wet type battery only
Wet lead acid battery requires periodic high voltage charging (about 10% overcharge absorption voltage) to balance the voltage of
each cell, reverse the high concentration of electrolyte at the bottom and clear up large sulfate crystals on the plates. You can use
the Calcium–Calcium selection to perform the manual equalization by carefully following the battery maker’s recommended
frequency and duration.
Make sure to manually switch off charger when time is up.
Take special precautions as battery will emit explosive gas during equalization charge.
F. Dual bank charging
This feature is for caravans, and vehicles with two separate batteries.
The two batteries must be of same chemical make up and type to avoid over and under charging because only one setting of
charging profile for both.
Two batteries are charged simultaneously and the battery with the lowest level gets most share of the current in the bulk charge
stage until it is up to the same voltage level of the second battery (battery with higher initial level).
Both batteries will go to the absorption and the float charge at the same time.
Fig.2
BATTERY
STATE OF
CHARGE
CHARGING
VOLTAGE
CHARGING
CURRENT
TIME
BULK CHARGE ABSORPTION CHARGE FLOATING CHARGE
3 - STAGE CHARGING DIAGRAM
S.O.C.
CONSTANT CURRENT CONSTANT VOLTAGE CONSTANT VOLTAGE

User’s manual
- 5 -
FUM – 2410/15/20CBP
G. Power supply / 2 stage charger mode (see Fig.3)
At this mode the Charger On (5) LED becomes red color and only bulk and float LED will function. The bulk LED will be off
when batteryis charged to about 80% full.
The 3 stage charger becomes a 2 stage charger or as power supply in this selected mode because 3 stage charger overcharges
battery with external load.
This selected mode is intended for use to charge battery with external load such as caravan or other battery and external load
combination.
A 2-stage charger can be used as a combination charger/power supply. An external load can draw current from the charger while
the charger is recharging a battery. The charger doesn't care how much current is being diverted by an external circuit as it
switches from bulk mode (constant current) to float mode based only on the battery terminal voltage.
However, a 2-stage charger cannot completely charge the battery when the charger switches from bulk mode to float mode. After
switching to float mode, the battery will, in most cases, be about 80% recharged. The battery receives the remaining recharge
while in float mode over several days.
It is highly recommended to switch back to the 3 stage charger mode periodically when the external load is disconnected.
Also the external load should not be more than 50% of the max. current of the charger, unless the battery is fully charged up. If the
bulk LED is on most of the time then the load is too large.
G1. As a stand alone power supply
It can also be used as a stand alone power supply without connection to a battery. It will provide a constant voltage according to
the selected float voltage (26.4/27.0/27.6V) and rated DC current of the charger.
However,itisnotrecommendedforhighsurgeload(suchaslamp)instandaloneapplicationastheinitial high surge current will
trigger the overload protection of the power supply.
Power supply / 2 stage charger mode application

User’s manual
- 6 -
FUM – 2410/15/20CBP
H. Temperature sensor
Warning:
The temperature sensor must be installed at the negative terminal of the battery terminals, wrong connection to the positive
terminal will damage the charger and the sensor.
The temperature sensor is available as an optional accessory (ATS-5120) and is used to optimal charging over wide ambient
temperature range.
Fix the temperature sensor (optional accessory) in a position on the battery which is not affected by other cooling or heating
source.
Plug in the temperature sensor before switch on the charger to activate the temperature control function, never plug in the charger
during charging.
I. Cable size selection
Wire size
(AWG)
Area
(mm²)
Maximum one-way
distancie for 2% voltage loss
(24V 15A)
Maximum one-way
distancie for 2% voltage loss
(24V 20A)
Maximum one-way
distancie for 2% voltage loss
(24V 25A)
10
5.26
4.65 m – 15.3 feet
3.50 m – 11.5 feet
2.80 m – 9.2 feet
8
8.37
7.31 m – 24 feet
5.48 m – 18 feet
4.39 m – 14.4 feet
6
13.3
11.58 m – 38 feet
8.84 m – 29 feet
7.01 m – 23 feet
4
21.2
18.29 m – 60 feet
13.71 m – 45 feet
10.97 m – 36 feet
2
33.6
29.26 m – 96 feet
21.94 m – 72 feet
17.68 m – 58 feet
1/0
53.5
46.94 m – 154 feet
35.35 m – 116 feet
28.04 m – 92 feet
2/0
67.4
58.52 m – 192 feet
43.89 m – 144 feet
35.05 m – 115 feet
4/0
107
85.95 m – 282 feet
64.62 m – 212 feet
51.51 m – 169 feet
Table: Selection of cable zise and length versus current.
Fig.5

User’s manual
- 7 -
FUM – 2410/15/20CBP
J. Trouble shooting
PROBLEM
INDICATIONS
POSSIBLE CAUSES
SUGGESTED SOLUTION
Charger does not
work.
Indicator lights not
turn on.
No AC power.
Check AC connections are correct.
AC input socket fuse blown.
Replace with correct AC fuse by qualified
electrician.
No DC output.
Charger ON LED
is not on, float and
fault LEDs are ON.
Output short circuit.
Check DC connections between charger and
battery.
Over temperature protection triggered.
Check air intake vent at bottom of charger
is blocked or not. Check charger ambient
ventilation.
Severe over loading charger.
Check battery Ah capacity within
recommended range.
Reverse polarity connection.
Check for correct polarity, replace car blade
fuse (7).
Battery does not
get full charge.
All indicator LED
work normally and
sequentially.
Bad battery connection.
Check for loose contact, right cable size,
cable integrity.
Battery type select switch in wrong
setting.
Recheck battery type and change to correct
battery selection.
Battery capacity too large.
Make sure charger rating matches battery
capacity. See table (B2).
Ambient temperature too low.
Move battery to a room temperature
location, or get an optional temperatura
sensor.
Battery has damaged cell or battery is
too old.
Replace battery.
Long charging
time, float light
does not come on
even after 20 hours
charging time.
Absorption light
remains on all the
time.
Wrong battery type selection eg. charge
gel battery with Calcium-Calcium or wet
type selection.
Check charged battery label and change
battery type selection to correct setting.
Total battery capacity is too high for
dual charging.
Check battery capacity or charge battery
separately.
Battery temperature too high.
Use temperature sensor (optional
accessory).
Battery is defective.
Replace battery.
A load is connected to battery and
charger is not in power supply mode.
Change charger selector switch (2) to power
supply mode.
Bulk LED is on all
the time.
Bulk light remains
on all the time
when charger is in
power supply
mode, LED(2) is
on red.
The connected load is too large, using
most of the current from the charger.
Reduce the load to about 50%of the
charger's rating current or take away the
load and set charger to battery charger
mode to fully charge the battery befote
return back to the power supply setting and
load connection.
Bulk light remains
on all the time
when charger is in
battery charger
mode, LED(2) is
on green.
Wrong battery type selection.
Check charged battery label and change
battery type selection to correct setting.
Battery is excessively depleted and the
soft charging is triggered.
Recharge the battery after a day, if bulk
light remains after several hours, the battery
is most likely damaged and cannot accept
charge. Replace battery.
Battery temperature too high.
Use optional accessory temperature sensor.

User’s manual
- 8 -
FUM – 2410/15/20CBP
K. Specifications
Model
FUM – 2410CBP
FUM – 2415CBP
FUM – 2420CBP
Output
Absorption charge voltage selections
Gel: 28.2V / AGM: 28.6V / Wet: 28.8V / Calcium-Calcium: 31.1V
Absortion charge timer
Limited not over 4 hours.
Float charge voltage selections
26.4V 27.0V 27.6V
Battery charger / power supply selections
Yes
Maximum output charging current
(continuous)
15A
20A
25A
Recommended battery capacity range
50~150 Ah
70~200 Ah
80~250 Ah
Soft start bulk charge
Battery voltage to trigger (cut-in) soft start
bulk charge mode
< 18V
Soft start bulk charge current (current limit)
7.5A
10A
10A
Line regulation (90~260V) for charging
current
< 0.5%
Ripple and noise (peak to peak)
< 250mV
< 250mV
< 250mV
Efficiency at maximum power (100/230VAC)
> 86/90%
> 86/90%
> 86/90%
Dual bank charging (battery must be of same
type)
Yes
Input
AC voltage range
100~260 VAC 50Hz
AC current at full load (100/230VAC)
5.6/2.4A
7.4/3.2A
9.3/3.9A
Protection
Overload
90~110% rated output current or 50% rated output current (soft
charge).
Protection type: constant current limiting, recovers automatically
after fault condition is removed.
Short circuit
Recovers automatically after fault condition is removed.
Reverse polarity
Car blade fuse.
Over temperature
Protecction type: shut down.
OVP output over voltage
Yes
Cooling
Cooling method
Thermostatic, Variable speed fan.
Indicators
3 stage battery charger / power supply mode
Yes
Charge phase bulk / absortion / float
Yes
Fault mode
Yes
A C p o w e r
Yes
Fuses
AC fuses at IEC AC power socket
T6.3A
T8A
T10A
DC car blade fuse at front panel
25A x 1
15A x 2
20A x 2
Accesories
Cable & spare fuses
Yes
Remote temperatura sensor
Optional
Approvals
Safety: EN 60335
Yes
EMC: EN 55014
Yes
Others
Dimensions and weight
220 x 80 x 200mm;
2.4Kg
220 x 80 x 250mm;
2.8Kg
220 x 80 x 261mm;
3.2Kg
Remar ks
All values are based on the standard ambient temperature 25°C and pressure 0.1Mpa
OR: 7673-2200-0012 Rev. 3.0 08/2009
TR: 24XX-CBP-BIG Rev. 3.0 08/2009