Manson Engineering Industrial SBC-5925 User manual

SBC-5925
12V / 24V Input with 12V Output
3 Stage DC-DC Charger
Operation manual
Keep this manual in a safe place for quick reference at all times.
This manual contains important safety and operation instructions 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.
Failure to heed this warning may cause injury to persons and damage to Equipment.
Failure to observe this warning may result in damage to equipment
and improper functioning of the Charger.
WARNING:
●The charger is not designed for any life saving application.
●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 based batteries and Lithium Fe PO4 (LFP).
●Don't recharging non-rechargeable 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.
●Never attempt to charge a frozen LEAD BASED battery.
Never attempt to charge LFP battery below minus five degrees C.
Never attempt to charge LFP (Lithium FePO4 ) without built in.
BMS (battery management System).
●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 give out explosive gas.
●Do not charge batteries in an enclosure (box- in) due to possible explosion of entrapped explosive gas.
●If the charger does not work properly or if it has been damaged, unplug all DC connections of input and
output.
Copy Right
All rights reserved.
No part of this publication may be reproduced, or transmitted in any form or by any means without the written
permission from Manson Engineering Industrial Ltd.
Changes in the manual.
Manson Engineering Industrial Ltd. has the right to update and change the content of this manual without
any prior notice and obligation.

Disclaimer
Exclusions for documentation, Indemnity and Product application.
Manson Engineering Industrial Ltd. (Manson)
1) Assumes no warranty to the accuracy, suitability of technical information given in the user manuals or
other documentation.
2) Undertakes no responsibility or liability of losses, damages and related expenses whether specific,
direct, indirect consequential or accidental which might result from the use of information given in this
manual.
3) Shall not be liable to anyone for any special, collateral, incidental or consequential damages in
connection with or from the use of these Manson products. The sole and exclusive liability to Manson,
regardless of the form of action shall not exceed the purchase price of the Manson product.

Table of content
Introduction
Features & Protections
Supplied Accessories
Installation Procedure
Indicators & Controls
Battery Type Selection
Connections
Charger Control Modes
Automatic Ignition Control
Manual Ignition Control
Vibration Sensor Control
Cancel Ignition Control
Input Voltage Control
Summary of 3 Control Modes Operation Voltages
Wiring Diagrams & Connections to LED Module
Specifications
Trouble Shooting

Introduction
Especially designed for vehicles with Smart Alternator, Start-Stop, Regenerative Braking system
The SBC-5925 is designed to address to the issues of wide swing of output voltages from the smart
alternator, braking regenerative EURO 5/6 vehicles in fully charging the house battery. It is suitable for use
with all old alternator system and distant house battery.
The charger Booster provides fast safe charging profiles for 4 types of lead based and 2 types of Lithium
FePO4 batteries.
The built-in vibration sensor makes it possible to use the charger by just connecting to the starter battery
terminal without touching the car’s electrical /electronic wiring thus avoiding any possible excuse of revoking
the car’s warranty.
The digital control design of SBC-5925 makes it automatically select & adapt to 12V or 24V input alternator/
battery system.
Multistage Charging
This is a select (battery type) and forget charger designed for fast and accurate recharge of your deep cycle
house battery. The smart multistage charging enables the charger to be connected permanently to your
battery banks without the worry of over charging or drying out the electrolyte.
Lead acid based Battery
A 3 Stage Bulk, Absorption & Float charging profile for 4 types of lead acid based battery with maximum
constant charging current at the Bulk Stage and a Constant Voltage with decreasing charging at the
Absorption Stage and a reduced voltage Float Charge for maintenance when battery is full.
LiFePO4 (LFP) Battery
A 2 Stage charging is specially for 2 types LiFePO4 battery and charging current stops at the end of
Absorption stage.
Three Charge Control Methods:
Ignition Control : Charger starts charging only when ignition is on and stops charging when
Ignition is off.
Vibration Sensor Control : Charger starts charging when repeated vibrations are detected and stops
charging when no vibration is detected for over 2 minutes.
Input Voltage Control : This is for non-intelligent alternator with sufficient high & uniform voltage.
Charging is cut off easily due to high threshold voltage to protect starting
battery.
Features
●Auto select for 12V or 24V car system.
●Design for all alternators, conventional, smart alternators, start-stop & regenerative braking.
●3 DC Charge Control Modes to select: Vibration Sensor Control Mode.
Ignition Control Mode with Automatic on when ignition is on &
off when Ignition is off or Manual Control setting.
Input Voltage Control.
●Suitable for standard Lead Acid, AGM and Lithium Fe PO4 battery.
●3 Stage charge for 4 types of Lead Acid based batteries.
●Specific 2 Stage charge for 2 types LiFePO4 battery.
Protections
●Self Recoverable Input Under Voltage Protection.
●Self Recoverable Output Over Voltage Protection.
●Self Recoverable Over Temperature Protection.
●Self Recoverable Over Load Protection (C.C.) with constant current at decreased output voltage.
●Self Recoverable Input Reverse Polarity Protection
●Output Reverse Polarity Protection by thermal fuse.

Supplied Accessories
●Remote LED Indicator Module (with 2M cable) like the unit front panel.
●4 heavy duty electrical eye connectors.
●One plastic wire guide.
●Double side sticker tape for the Remote Indicator Module.
●Two thin wires for Pin Connections
●One spare 8 Pin Connection sticker label
Installation Procedure
Do NOT install this unit in the vehicle engine bay.
This is a fan cooled electronic device not for use in high temperature, corrosive and dusty environment which
will drastically shortens the life and performance of the charger.
This charger is designed only for internal mounting and away from direct sunlight, heat and rain. Allow at
least 80mm of space at both ends for ventilation.
We recommend wiring by a qualified automobile electrician to ensure local safety and on-board standard are
followed
1. To provide the best cooling effect, mount the unit in vertical position with the terminal end facing
downwards due to the top front exhaust design.
2. First install the charger as close to the house battery as possible via a fuse.
3. See Quick Start Guide to select battery type and charge functions.
4. Before connect input to DC Alternator, check on type of alternator of car, for new car with smart
alternator select ether Vibration Sensor Mode or Ignition Control Mode.
5. Do not charge LFP battery without built in Battery Management System.
6. Do not charge LFP battery below minus 5C.

Figure: correct installation direction
Indicators and Controls
Figure: 7 LED display
SET button
The SET button is for selection of battery & deactivate Ignition Control Mode.
Long press for 5 second for battery selection and long press for 15 second to deactivate Ignition Control
Mode.
Charging Status LED for LEAD ACID Battery - 3 Stages
Charging status LED
Charging stage
Fast flashes
Bulk charge
Slow flashes
Absorption
Solid
Float
Charging Status LED for Lithium Fe PO4 Battery - stages
Charging status LED
Charging stage
Fast flashes
Bulk charge
Slow flashes
Absorption

Output Voltage LED
This LED shows the voltage level at the V OUT terminal.
It becomes the battery voltage when there is no Load connected to the battery and no input voltage.
LED status
Battery Voltage Level
Fast Flashes
Battery Voltage lower than 12.5V
Slow Flashes
Battery Voltage between 12.5V and 13.6V
Solid
Battery Voltage higher than 13.6V
Battery Type Selection
1. Press and hold the only Set Button for about 5 seconds until the LED flashes.
2. Quick presses will move the LED in cyclic order from Lead--> AGM--> LFP-->Type2 + Lead --> Type2 +
AGM --> Type2 + LFP --> Lead-->AGM-->LFP….
3. Stop at the chosen battery type and wait till LED turns to solid to lock in your selection.
Connections
Allow 10 seconds delay time after connections are done correctly with proper input & output voltage for
selected charge control.
Fig.3 Terminals & 8 PIN connectors
1 T+: Vibration sensor enable pin. Connect to Vout for Ignition pin to enable Vibration
sensor control. .
2 Red: Connection to remote module Red wire.
3 Green: Connect to remote module green wire.
4 Yellow: Connect to remote module yellow wire.
5 Alarm: Alarm output pin. 12V 50mA for external alarm.
6 GND: Ground pin for remote module. Connect to remote control black wire.
7 Ignition: Connect this pin to ignition car ignition to make the charger operate in sync with
vehicle ignition control.
8 Vout for Ignition: 12 Voltage signal.
Short this pin to pin 7 (Ignition) to enable manual ignition control of unit to ON.
Short this pin to Pin1( T+ ) to enable vibration sensor mode.
*This pin is for Ignition and Vibration sensor only. Don’t connect to other devices.

Charger Control Modes
There are 3 automatic charge modes plus one manual ON-OFF to switch on and off the charger to give the
optimal charging current to the auxiliary battery.
Automatic Ignition Control Mode
Automatic Ignition Control
It synchronizes ON/OFF of the DC-DC charger.with the car’s ignition.
This mode requires connection to the car’s Ignition Signal Terminal 15 see wiring diagram page 10 electrical
circuit which gives out a positive DC Voltage from the car’s electrical wiring when the ignition is tuned
on .The ignition control will set to ON once the Ignition Pin 7 is applied with 9-32V voltage. The charging
operation stops when Ignition is off & engine stops running.
This mode is recommended for all alternator type including Europe 6, 6+plus with start/ stop energy saving.
Manual Ignition Control
You can wire a contact switch with one end to the Ignition Pin 7 and the other to Vout for Ignition Pin 8.
Shorting both pins will turn on the charger, disconnect will turn off the charger.
Vibration Sensor Control Mode
The built in vibration sensor with special software control turns on the charging when trains of vibrations are
detected. Installation is simple and quick and without touching the car’s electrical system for the sensor to
work.
Enable build-in vibration sensor
The built-in vibration sensor is enabled by connecting T+ Pin1 to Vout for Ignition Pin 8.
The vibration sensor is in standby mode with output is OFF (no charging). When sensor is triggered by a
series of vibrations which switch on the charger. The charging output will be switched ON for about 100
seconds continuously.
Any further vibration during the 100 seconds active mode, will extend the output ON for another 100 seconds.
The output will be OFF if no more vibration detected within 100 seconds of last vibration.
Over ride of all Control Modes by Vibration Sensor Control
Built-in vibration sensor when enabled, dominates the control of output and overrides all other Control Modes
including the Ignition Control. That is only vibration can make the charger start charging with output ON.
To disable the Vibration Sensor: Take out the connection between the Pin1(T+) from Pin 8 (Vout for
Ignition).
CAUTION: DO NOT USE VIBRATION SENSOR CONTROL WHEN CAR IS ON FERRY, TRAIN OR
OTHER TRANSPORT PLAFORM.
REMARK
Once the Vibration Sensor Mode is disabled , the charger will return to the last selected mode.

Cancel Ignition Control
i) Take out connection to the Ignition pin.
ii) Press and hold button for around 15 seconds until the 3 LED battery type flash at the same time.
iii) Release button and charger is changed to Input Voltage Control.
Input Voltage Control Mode
This mode requires increased voltage (>13.4V) of the starter battery which is only possible with short thick
cable connection and a non-intelligent alternator with sufficiently high and stable charging voltage. This
Control Mode is not suitable for modern cars due to wide voltage range such as Euro 5/6.
Cancel the Ignition Control first in order to get into this mode.
Summary of 3 Control Modes Operation voltages
CHARGE MODE
12V CAR
24V CAR
Input Voltage
Output Status
Input Voltage
Output Status
Vibration Sensor Mode
< 9V
> 11V
Cut OFF
Resume to On
< 18V
> 22V
Cut OFF
Resume to On
Ignition Control Mode
< 9V
> 11V
Cut OFF
Resume to On
< 18V
> 22V
Cut OFF
Resume to On
Input Voltage Control Mode
< 12.8V
> 13.5V
Cut OFF
Resume to On
< 25.6V
> 27.0V
Cut OFF
Resume to On
The Ignition Control and Vibration Sensor modes are suitable for Constant Voltage Alternators, Smart
Alternators, Start Stop, Euro 5 and 6 engines, cars with Regenerative Braking.

Wiring Diagram & connection to Remote LED Module
Individual fuse/ breaker is required to be close to starting battery (charger input) and close to house battery
(charger output wire).
Figure: Connection diagram
Ignition Signal
Terminal 15
(DIN 72552)

Specification
Rated output power
25A at 13.8VDC
Optimal Efficiency
≥89%
Input Voltage
DC Input Voltage Range
9 - 16VDC (12VDC Input) / 18 - 32VDC (24VDC Input)
Max. Solar Panel Open Circuit Voltage
30VDC
No load input current
<50mA
Output (Charge) Voltage
Battery Type
Absorption
Float
Lead
14.4V
13.3V
Lead 2
14.6V
13.5V
AGM
14.2V
13.1V
AGM 2
14.7V
13.6V
LiFePO4
14.4V
Stop
LiFePO4 2
14.8V
Stop
Alarm Output
12V / 50mA
Size(W x L x H)
130x200x55 mm
Weight
Approx. 870g
Operation Temperature
-10 to +40ºC (Ambient Temperature)
Operating Mode
12V CAR
24V CAR
Input
Voltage
Output Status
Input
Voltage
Output Status
Vibration Sensor Mode
< 9V
> 11V
Cut OFF
Resume to On
< 18V
> 22V
Cut OFF
Resume to On
Ignition Control Mode
< 9V
> 11V
Cut OFF
Resume to On
< 18V
> 22V
Cut OFF
Resume to On
Input Voltage Control Mode
< 12.8V
> 13.5V
Cut OFF
Resume to On
< 25.6V
> 27.0V
Cut OFF
Resume to On

Trouble Shooting
The Fault LED is solid on when a protection is triggered and output of the charger is off. When the cause of
the fault has been clear up, Fault LED becomes off and charger returns to normal operation. Almost all the
protections are by software design and self recoverable, once the cause of fault has been dealt with. There
are two layers of protection for Input and Output Over-Voltage, the frst layer is by software and the second
layer by hardware as a double insurance to protect the charger and the connected devices.
Problem
Indication
Possible Causes
Suggested Solution
Recovery Condition
Low Voltage
Disconnect (LVD)
Ignition Control is not
set to Auto ON
Fault LED ON
12V battery system:
Input voltage <12.8V for
20s.
Check the starter
battery voltage.
Use correct size cable
between charger and
starter battery.
12V battery system:
Automatic recovery
when input voltage
rises above 13.4V for
60s.
Fault LED ON
24V battery system:
Input voltage <25.6V for 20s
24V battery system:
Automatic recovery
when input voltage
rises above 26.8V for
60s.
Low Voltage
Disconnect (LVD)
Ignition Control is set
to Auto ON
Fault LED ON
12V battery system:
Input voltage <9V for 5s
Check the starter
battery voltage.
Use correct size cable
between charger and
starter battery.
12V battery system:
Automatic recovery
when input voltage
rises above 11V for 5s.
Fault LED ON
24V battery system:
Input voltage <18V for 5s
24V battery system:
Automatic recovery
when input voltage
raise above 22V for 5s.
Output Over Voltage
Protection (Output
OVP)
Two layers of
protection
First layer by software
Second layer by
hardware
Fault LED ON
Software OVP:
Output terminal voltage >set
absorption Voltage +0.6V
for 2s.
Disconnect any load to
battery and check
battery voltage.
If no load connected to
battery in first place.
Check battery voltage
if over set absorption
voltage, disconnect
battery.
Software OVP:
Automatic recovery
when the voltage on
output terminal is
reduced below
absorption Voltage
+0.3V for 3s.
Fault LED ON
Hardware OVP:
Output terminal voltage
>17.0V.
FUSE will blow.
Hardware OVP:
Does not automatic
recovery
Required to replace the
blown FUSE.
Input Over Voltage
Protection (Input OVP)
Two layers of
protection
First layer by software
Second layer by
hardware
Fault LED ON
PV LED may
also be on at the
same time.
Software input OVP:
Charger output will be
shutdown when input DC
voltage higher than 32V.
Check input battery
voltage is not higher
than 32V.
Software Input OVP:
Automatic recovery
when the voltage on
input terminal is
reduced below 31.5V
for 5s.
Input Over Voltage
Protection (Input OVP)
by hardware.
All LEDs OFF
including the
FAULT LED.
Hardware Input OVP:
The FUSE will blow when
input terminal voltage higher
than 33.5V.
Find out about the
Input source condition
& spec such as
voltage surge etc.
Before replacing with
the new fuse.
Hardware input OVP:
Does not automatic
recovery
Required to replace the
blown
FUSE.
Over Temperature
Protection (OTP)
Fault LED ON
Charger internal
temperature is too high.
Check input & exhaust
ends have no
blockage and
a minimum 10mm
clearance.
Automatic recovery
when charger
temperature reduce to
normal level.
FAN fault
Fault LED ON
FAN not working
Check for objects
jamming fan or Fan is
out of order.
Remove objects which
jamming
the fan .
2019/05 Rev.1
7673-5925-0561