Manson Engineering Industrial SBC-5936 User manual

SBC-5936
24V In-Car Charger
Dual Input (Solar MPPT & DC)
peration 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.
WAR I G:
● 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 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 or Lithium FePo4 battery below 0 C.
● 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.
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 P.4
Features P.4
Protections P.4
Supplied Accessories P.5
Installation Procedure P.5
Indicators and controls P.6
Battery Type selection P.7
Solar panel and DC source dual inputs P.7
Charger control odes P.8
Connect & Wiring Diagra P.10
Specification P.11
Troubleshooting P.12
Figure index
Fig. 1 correct installation direction P.6
Fig. 2 7 LEDs indicators and one SET button P.6
Fig. 3 Terminals & 8 PIN connector P.7
Fig. 4 Connection Diagram P.10

Introduction
Especially designed for vehicles with Smart Alternator, Start-Stop, Regenerative Braking system
This charger is designed to deal with the issue of wide swing of output voltages fro the s art alternator,
braking regenerative EURO 5/6 vehicles in fully charging the house battery. It is suitable for use with all old
alternator syste and distant house battery.
The built-in vibration sensor akes it possible to use the charger by just connecting to the starter battery
ter inal without touching the car’s electrical /electronic wiring thus avoiding any possible excuse of revoking
the car’s warranty.
The digital control and auto-select design of SBC charger ake it auto atically adapt to 12V or 24V input
alternator/ battery syste .
Multistage Charging Process
This is a select (battery type) and forget charger designed for fast and accurate recharge of your 24V lead
acid deep cycle or Lithiu Fe Po4 house battery. The s art ulti-stage charging enables the charger to be
connected per anently to your battery banks without the worry of over charging or drying out the electrolyte
of lead acid battery.
Lead Acid Based Battery
A 3 Stage Bulk, Absorption & Float charging profile with axi u constant charging current at the Bulk
Stage and a Constant Voltage with decreasing charging current at the Absorption Stage and a reduced
voltage Float Charge for aintenance when battery is full.
LiFeP 4 (LFP) Battery
A 2 Stage charging is specially for the 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 inutes.
Input Voltage Control : This is for non-intelligent alternators with sufficient high & unifor voltage.
Charging is cut off easily due to high threshold voltage to protect the starting
battery.
Features
● Dual input fro car battery with alternator input and Solar panel.
● Auto select for 12V or 24V car syste .
● Design all alternators, conventional, s art alternators, start-stop & regenerative braking.
● 4 DC Charge Mode Selection 1. Vibration Sensor Control Mode.
2. Ignition Control Mode with Auto atic on when ignition is on
and off when Ignition is off
3. Manual on /off Control of charger by external switch connection
( see page 10 fig 3 ).
4. Direct connection to the car ‘s battery using its Voltage
levels for auto atic on and off of charger
● Suitable for standard Lead Acid, AGM and Lithiu Fe PO4 battery.
● 3 Stage charge for Lead Acid based batteries.
● Specific 2 Stage charge for LiFePO4 battery.
Protections
● Self Recoverable Input Under Voltage Protection.
● Self Recoverable Output Over Voltage Protection.
● Self Recoverable Over Te perature 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 ther al fuse.
P.4

Supplied Accessories
● Re ote 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 Re ote 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 te perature, corrosive and dusty environ ent which
will drastically shortens the life and perfor ance of the charger.
This charger is designed only for internal ounting and away fro direct sunlight, heat and rain. Allow at
least 80 of space at both ends for ventilation.
We reco end wiring by a qualified auto obile electrician to ensure local safety and on-board standard are
followed
1. To provide the best cooling effect, ount the unit in vertical position with the ter inal 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. Check the LED indicators by a few presses on the Select Button.
4. Before connect input to DC Alternator, check on type of alternator of car, for new car with s art
alternator select ether Vibration Sensor Mode or Ignition Feed Mode.
5. Do not charge LFP battery without built in Battery Manage ent Syste .
6. Do not charge LFP battery below 0°C.& discharge below inus 5°C. Check with battery aker.
P.5

Fig. 1: correct installation direction
Indicators and Controls
Fig. 2: 7 LEDs indicators and one SET button
SET button
The SET button is for selection of battery & deactivate Ignition Control Mode.
5 second long press for battery selection.
15 second long press 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 P 4 Battery – 2 Stages
Charging status LED Charging stage
Fast flashes Bulk charge
Slow flashes Absorption
utput Voltage LED
This LED shows the voltage level at the V OUT ter inal, it is the battery voltage when there is no Load
connected to the battery.
LED status Battery Voltage Level
Fast Flashes Battery Voltage level is low
Slow Flashes Battery Voltage level is medium
Solid Battery Voltage level is high
P.6

PV LED
The PV LED is ON when voltage fro PV panel is >14.4V. PV LED flickers with the changes of PV
voltages. PV LED is off at night ti e .This is a good way to check for open- circuit in the solar connection in
day time.
Battery Type Selection
1. Press and hold the only Set Button for about 5 seconds until the LED flashes.
2. Light quick presses will ove the LED fro Lead--> AGM--> LiFePO4--> Lead.
3. Stop at the chosen battery type and wait till LED stops flashing to confir your selection.
Connections
After both input and output are connected, the charger will have output after 10 Sec.
Fig 3. : Terminals & 8PI connectors
1 T+: Vibration sensor enable pin. Connect to Vout for Ignition pin to enable Vibration
sensor control.
2 Red: Connection to re ote odule Red wire.
3 Green: Connect to re ote odule green wire.
4 Yellow: Connect to re ote odule yellow wire.
5 Alarm: Alar output pin. 12V 50 A for external alar .
6 GND: Ground pin for re ote odule. Connect to re ote control black wire.
7 Ignition: Connect this pin to ignition car ignition to ake the charger operate in sync with
vehicle ignition control.
8 Vout for Ignition: Short this pin to pin 7 (Ignition) to enable anual ignition control of unit to ON.
Short this pin to Pin1( T+ ) to enable vibration sensor ode.
*This pin is for Manual On/Off or Vibration sensor only. Don’t connect to other
devices.
Solar panel and DC source Dual inputs
The charger supports 12V Solar panel and 12V or 24V DC source inputs. Both inputs can be connected
si ultaneously to the charger or either one. Charger uses Solar energy as priority source to charge battery
to axi ize the usage of Solar panel. The PV LED and charging output will be switched ON whenever the
Solar panel has sufficient energy for charging. The Vibration sensor, auto atic ignition control and anual
on off control have on effect on solar panel input charge.
*The allowable axi u power rating of solar panel is 400 Watt with axi u 30V Open Circuit voltage.
P.7

Charger Control Modes
There are 3 auto atic charge odes plus one anual ON-OFF to switch on and off the charger to give the
opti al charging current to the auxiliary battery.
Automatic Ignition Control Mode
It synchronizes ON/OFF of the DC-DC charger with the car’s ignition.
This ode requires connection to the car’s Ignition Signal Terminal 15 see wiring diagra (page 10)
electrical circuit which gives out a positive DC Voltage fro the car’s electrical wiring when the ignition is
turned 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 ode is reco ended for all alternator types including Europe 6, 6+plus with start/ stop energy saving.
Manual 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.(page 9)
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 si ple and quick and without touching the car’s electrical syste for the sensor to
work.
Enable build-in vibration sensor
The built-in vibration sensor is enabled by connecting the T+ pin 1 to Vout for Ignition pin 8.
Initially the charger output is off when the vibration sensor is in standby ode. Continuous vibrations with
over 8 inute duration triggers it into the active ode . The output will be switched ON for about 100
seconds continuously. Any further vibration during the 100 seconds active ode, will extend the output ON
for another 100 seconds. The output will be switched OFF if no ore vibration within 100 seconds of last
vibration.
ver- riding Ignition Feed by Vibration Sensor
Built-in vibration sensor when enabled do inates the control of output and over- rides all other Modes
including the Ignition Feed. That is only vibration can ake the charger start charging with output ON.
To disable the Vibration Sensor: Take out the connection between the T+ pin 1 fro Vout for Ignition
pin 8.
CAUTIO :
DO OT USE VIBRATIO SE SOR CO TROL WHE CAR IS O FERRY, TRAI OR
OTHER TRA SPORT PLATFORMS WITH REGULAR VIBRATIO S & SHOCKS.
REMARK
Once the Vibration Sensor Mode is disabled, the charger will return to the last selected ode.
If you are not sure about your last selected ode, you can set the charger to your desired ode.
P.8

Cancel Ignition Control
I) Take out connection to the Ignition pin 7.(page 8 )
ii) Press and hold button for around 15 seconds until the 3 LED battery type flash at the sa e ti e.
Iii) Release button and charger changes to Input Voltage Control.
Input Voltage Control Mode
This ode requires increased voltage (>13.4V) of the starter battery which is only possible with short thick
cable connection and old type alternator with sufficiently high and stable charging voltage. This Control Mode
is not suitable for odern cars due to wide voltage range such as Euro 5/6.
Cancel the Ignition Control first in order to get into this ode.
Summary of 3 Control Modes peration voltages
CHARGE MODE 12V CAR 24V CAR
CHARGE ON CHARGE OFF CHARGE ON CHARGE OFF
Vibration Sensor Mode
when sensor is triggered by ibration
from car
11-16V <9V 22-32V <18V
Ignition Feed – Automatic Mode
connect to Ignition switch when
Ignition is on
11-16V <9V 22-32V <18V
Factory Preset Mode
Vibration Sensor & Ignition Feed
Inacti e
12.8-16V <12.2V 25.6-32V <24.4V
P.9

Connect & Wiring Diagram
Individual fuse/ breaker is required to be close to starting battery (charger input) and close to house battery
(charger output wire). Fuse at the solar panel to the rating of the short circuit current of the solar panel.
Fig. 4: Connection Diagram
P.10

Specification
Rated output power 12A at 27.6VDC
Efficiency ≥90%
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 <25 A
Output (Charge) Voltage
Battery Type Absorption Float
Lead 27.6V 26.6V
AGM 29.4V 27.2V
LiFePO4 29.6V Stop
Alar Output 12V / 100 A
Size(L x W x H) 130 x 188 x 55
Weight Approx. 870g
Operating Te perature -10 to +40ºC (A bient Te perature)
Reco ended Cable Size
Cable Length Reco ended SAE
1 – 5 Meters 8AWG
5 – 9 Meters 6AWG
Operating Mode
12V CAR 24V CAR
Vibration Sensor Mode Charge ON
11-16V
Charge OFF
<9V
Charge ON
22-32V
Charge OFF
<18V
Ignition Feed – Auto atic Mode Charge ON
11-16V
Charge OFF
<9V
Charge ON
22-32V
Charge OFF
<18V
Factory Preset Mode Charge ON
12.8-16V
Charge OFF
<12.2V
Charge ON
25.6-32V
Charge OFF
<24.4V
Reco ended PV Panel Size
PV Panel Size 400Watt with axi u 30V open circuit voltage
P.11

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 beco es off and charger returns to nor al operation. Al ost 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 first 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 syste :
Input voltage <12.8V for
20s.
Check the starter
battery voltage.
Use correct size
cable between
charger and starter
battery.
12V battery syste :
Auto atic recovery
when input voltage
rises above 13.4V for
60s.
Fault LED ON 24V battery syste :
Input voltage <25.6V for
20s
24V battery syste :
Auto atic 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 syste :
Input voltage <9V for 5s
Check the starter
battery voltage.
Use correct size
cable between
charger and starter
battery.
12V battery syste :
Auto atic recovery
when input voltage
rises above 11V for
5s.
Fault LED ON 24V battery syste :
Input voltage <18V for 5s
24V battery syste :
Auto atic 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 ter inal 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:
Auto atic recovery
when the voltage on
output ter inal is
reduced below
absorption Voltage
+0.3V for 3s.
Fault LED ON Hardware OVP:
Output ter inal voltage
>34.0V.
FUSE will blow.
Hardware OVP:
Does not auto atic
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 ay
also be on at
the sa e ti e.
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:
Auto atic recovery
when the voltage on
input ter inal 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 ter inal 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 auto atic
recovery
Required to replace
the blown
FUSE.
Over Te perature
Protection (OTP)
Fault LED ON Charger internal
te perature is too high.
Check input &
exhaust ends have
no blockage and
a ini u 10
clearance.
Auto atic recovery
when charger
te perature reduce to
nor al level.
FAN fault Fault LED ON FAN not working Check for objects
ja ing fan or Fan
is out of order.
Re ove objects which
ja ing
the fan .
P.12
REV.0 20200311
7673-5936-0560