Manson Engineering Industrial ZPS-9160 User manual

ZPS-9160/9230/9320/9415
Charger Power Supply for Car Showroom & Workshop
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 attery charger.
Read through the manual and pay special attention to the markings
and la els of the charger, attery and equipment connected to the attery system.
Pay special attention to WARNING & PRECAUTIONS used in this manual.
REV.2 2020/06
7673-9160-0002

P. 2

Warning/ Cautions
WARNING:
ailure to heed this warning may cause injury to persons and damage to Equipment.
CAUTION:
ailure 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.
● The charger is made to charge only properly sized lead acid batteries and Lithium iron phosphate (LiFeP 4).
● 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.
● 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 give out explosive gas.
● peration as batteries may give out 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 all connections.
● This appliance can be used by children aged from 8 years and above and persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or
instruction concerning use of the appliance in a safe way and understand the hazards involved.
● Cleaning and user maintenance shall not be made by children without supervision.
● Children should be supervised to ensure that they do not play with the appliance.
● State that during charging, the battery must be placed in a well-ventilated area.
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.
P. 3

Introduction
The large num er of electronic devices in modern vehicles presents a challenge to the
presentations of vehicles in the show room as customers want to view & try out out most of the
functions.
The starting attery which is not eing charged y the alternator at the same time, will e used up.
Normal car charger is not designed for such situation which causes the attery go through charge
cycles.
This charger is the solution to discharged starter atteries during showroom demonstrations.
The specially developed dc supply/charger with software prevents unwanted charge & discharge
cycles of the starter attery. A safe clean and relia le dc source of power to ensure the attery is
maintained in a top condition for continuous professional presentation.
The 60Amp rated power supply mode with adjusta le current limit and 12V to 15V voltage range
to meet different demands of DC power for different size atteries and frequency of
demonstrations.
(remark : 12V to 15V and 60Amp is for ZPS-9160, refer to specification for other models)
In the Workshop, the charger can e used as a 5 Stage charger with specific charging profiles for
Lead ,AGM 2, and LiFePO4 attery types. maximum charging current is adjusta le from 5 to
60Amp to provide the optimal charging current level for a wide range of attery sizes.
Power Supply mode is also used during flashing (updating) of the car’s computer system.
(remark : 5 to 60Amp is for ZPS-9160, refer to specification for other models)
Indication
Indicate Battery type selected
Indicate WiFi/ DC supply mode/ Charger and Equalization charge on/off status
Output Voltage and Current Displays, Display information during setting stages
UP/ DOWN and SETUP uttons
P. 4

Dimension
oldable stand
There are two main application modes: the Power Supply Mode mainly for car showroom
application, the Charger Mode for workshop.
Power supply mode
The Power Supply Mode is used for Showroom application and flashing (updating) of the car’s
computer system in workshop. It provides a sta le constant voltage (12 to 15V) with up to 60Amp
output. The adjusted setting of voltage and current will e retained even after AC mains and output
are disconnected allowing an easy daily showroom operation y switching just the mains switch.
Power supply mode features & setting list
Features Display Range
Set output voltage 12V to 15V at 0.1V step
Set max. output current limit 0A to 60A
Set display rightness 3 Levels {1, 2, 3}
Set output ca le length 0, 2, 3, 5meters
0 means no compensation
Save & exit
Exit without save
(remark : 12V to 15V and 60Amp is for ZPS-9160, refer to specification for other models)
P. 5

Charger Mode
Three types of charging profiles to select : Lead, AGM 2 & LiFePO4.
Only the output current limit can e set etween 5-60A at 0.5A step for different attery size.
This feature greatly increases the optimal range of suita le attery capacities.
Always set the output current limit according to the recommendation of the battery
manufacturer.
The following ta le is just for general references.
Lead ased atteries require longer full charge time (8-10 hours) with optimal charging current.
LiFePO4 attery can take up more charging current ( 0.5 -1C) in a shorter time as it
solely depends on the design of BMS ( attery management system)of the attery.
Ta le 1: Charge current for suita le attery size
Max. output current 5Amp 10Amp 20Amp 30Amp 60Amp
Lead & AGM 2 Battery 20-50AH 40-100AH 80-200AH 120-300AH 240-600AH
LiFePO4 Battery 10-50AH 20-100AH 40-200AH 60-300AH 120-600AH
Charger mode charging profiles & setting list
Lead acid attery
Charging profile : Soft Start / Bulk / A sorption / Equalization / Float
Setting list
Features Display Range
Set max. output current limit 5A to 60A
Set equalization charge On / Off
(EQ is 16V and 5A. Max. 1hr)
Set display rightness 3 Levels {1, 2, 3}
Set output ca le length 0, 2, 3, 5meters
0 means no compensation
Save & exit
Exit without save
( remark : 5 and 60Amp is for ZPS-9160, refer to specification for other models )
P. 6

AGM 2 attery
Charging profile : Soft Start / Bulk / A sorption / Float
Setting list
Features Display Range
Set max. output current limit 5A to 60A
Set display rightness 3 Levels {1, 2, 3}
Set output ca le length 0, 2, 3, 5meters
0 means no compensation
Save & exit
Exit without save
(remark : 12V to 15V and 60Amp is for ZPS-9160, refer to specification for other models)
LiFePO4 attery
Charging profile : Soft Start / Bulk / A sorption
Setting list
Features Display Range
Set max. output current limit 5A to 60A
Set display rightness 3 Levels {1, 2, 3}
Set output ca le length 0, 2, 3, 5meters
0 means no compensation
Save & exit
Exit without save
(remark : 12V to 15V and 60Amp is for ZPS-9160, refer to specification for other models)
Equalization charge mode for lead acid battery
This is intentional over-charging is mainly for flood lead acid attery to remove sulfation that
formed either due to frequent under charge or inactivity with long period of self discharge.
Before setting up of Equalization Charge ,all loads on attery terminals must e removed and
attery electrolyte is filled up. EQ charge is set to occur right after A sorption charge for 60
minutes at voltage of 16 V and current is limited to 5 Amp.
Charger will go to Float charge after equalization charge.
(remark : 16V and 5Amp is for ZPS-9160, refer to specification for other models)
P. 7

Li ePO4 battery
All LiFePO4 attery anks have uilt-in BMS ( Battery Management System).
The BMS monitors & controls: the safety functions, max charging current, max input voltage and
other discharge safety feature of the attery.
Always follow strictly to the warning, precautions and recommended max charging parameters,
temperature from the attery manufacturer.
The charging and discharge profile of LiFePO4 is very much different from the lead ased
atteries.
There is a high possi ility of over-discharging the attery ecause of the sta le discharge voltage
range (13.2v to 12.8V) for 80% of its capacity, its output voltage is 12.5V even at last 10% attery
capacity. There is no need to fully charge up the attery, in fact LiFePO4 attery prefers to e at
80%.
It can take in 0.5 C easily and up to 1C charging for most BMS design.
Do not charge LiFeP 4 below zero centigrade.
Step by step examples of operation & setting
When unit is powered up, the displays first show the present firmware version then current and
voltage depending on the last set Mode of the unit and whether output is connected.
Example 1 : Set maximum charging current limit when unit is in AGM 2 charger mode
i. Press and hold the until appear.
ii. Press the and display show .
iii. Press the to enter display.
25.5 Amp is the present max., press or to increase or decrease the value.
iv. Press to confirm new current setting,and display change to: .
Caution: Setting procedure is not completed and must go through Display Brightness &
Output Ca le length to confirm at the Save & Exit stage .
v. Press the to scroll through display rightness setting & output
ca le length setting to arrive at Save & Exit stage .
vi. Press to confirm and save your new settings.
If you do not want to save any of the new settings, you could go one step further to Exit
without save and press utton. Alternatively, you just stop press
any utton for 30 sec, unit will exit without save.
You can change settings of display rightness and output ca le length using same procedure like
setting the max. current limit.
P. 8

Example 2 : Changing the Application Mode
Change to DC Supply Mode
i. Press and hold the until appear.
ii. Press the to enter .
iii. Press or to cycle: LEAD > AGM 2 > LiFePO4 > DC Supply > LEAD > AGM 2 >…..
Take note of the LEDs on right panel changes with a ove settings.
Let us select DC Supply application mode.
iv. Press to confirm at .
v. Press and set voltage appears .
vi. Press the to view or change the flashing voltage .
vii. Press to increase or decrease voltage.
viii.Press utton to confirm new voltage setting, display ecomes .
ix. Press to go to Current Setting .
x. Press the to view or change the current setting .
xi. Press to increase or decrease current setting.
xii. Press[Menu] utton to confirm new current setting, display ecomes .
Caution: Setting procedure is not completed and must go through Display Brigtness &
Output Ca le length to confirm at the Save & Exit stage .
xiii.Press the to scroll through display rightness setting & output
ca le length setting to arrive at Save & Exit stage .
xiv.Press the utton to confirm and save your new settings, only the voltage meter will
display the set voltage if output is not connected.
P. 9

Charging Cable Length Setting
These settings provide compensation for voltage drop across a 8 AWG charging ca le of 2 / 3 / 5
charging ca les in high current application. The zero setting has no compensation effect.
It is recommend to check on the internet for the appropriate ca le size for specific length.
Suggested ca le size for different maximum output current
Maximum current 10A 20A 40A 60A
Ca le size 16 AWG 12 AWG 10 AWG 8 AWG
Selection Steps:
When Display shows ,
Press to enter. Then press uttons for Displays : {Len} {2} {3} {5} {0} selections.
Press utton to confirm selection.
Display Brightness Setting
The displays have 3 rightness levels for showroom and workshop environment.
The dim setting is for least distracting in car showroom.
Selection Steps:
When Display shows ,
Press to enter. Then press uttons for Displays : {Led} {1} {2} {3} selections.
Press utton to confirm selection.
Installation
The slim casing (82mm) allows it to under most cars in the showroom.
The adjusta le stands at the ottom provide easy viewing with 3 rightness setting of display.
The unit can e installed horizontally or vertically.
This charger use low profile design with only 82mm height. This form factor make it is easily to e
installed under any type of car within show room environment. The charger allowed to e installed
horizontally or vertically.
Connect AC Input
This unit supports input range from 100VAC to 240VAC. Please check the AC source rating is
within the range efore connecting to the mains.
Connect DC output
The charger has 2 different output socket versions. Anderson plug or Traditional terminal. Connect
the ca le to DC output terminal with compati le terminal.
P. 10

- Anderson plug
- Traditional terminal
Select correct output cable length
The charger has automatic voltage compensation feature. The value of compensation depends on
ca le length and output current. To get the est performance on compensation, it allows you to
select 3 different length of ca les. It can e selected in menu for 2m, 3m or 5m of AWG 8 ca les.
See section “Charging Cable Length Setting” page 9 for more details. The ca le with compati le
terminal types can e ordered from Manson.
P. 11

Wi i Connection
The WiFi is always ON. Use Smartphone Apps to connect charger for remote monitoring. The WiFi
LED will ON when it is connected smartphone or router.
Smartphone Apps
There are Apps for iOS and Android can e used to monitor Manson ZPS-series Battery Charger.
Please go to App Store or Google Play to search “Magnett Charger Monitor” apps.
P. 12

Specifications
Model ZPS-9160 ZPS-9230 ZPS-9320 ZPS-9415
AC input Voltage 110-240VAC 50/60Hz
AC input Current <5A @ 230VAC
No Load Input Current ≤320mA
Output Voltage
Lead A sorption : 14.4V
Float : 13.6V
A sorption : 28.8V
Float : 27.2V
A sorption : 43.2V
Float : 40.8V
A sorption : 57.6V
Float : 54.4V
AGM 2 A sorption : 14.7V
Float : 13.6V
A sorption : 29.4V
Float : 27.2V
A sorption : 44.1V
Float : 40.8V
A sorption : 58.8V
Float : 54.4V
LiFePO4A sorption : 14.4V
Float : OFF
A sorption : 28.8V
Float : OFF
A sorption : 43.2V
Float : OFF
A sorption : 57.6V
Float : OFF
DC Supply 12V – 15V (0.1V step) 24V – 30V (0.1V step) 36V – 45V (0.1V step) 48V – 60V (0.1V step)
Output current range 5 – 60A 2.5A – 30A 2.5A – 20A 2.5A – 15A
Soft Start Bulk Charge Half of set current
(max. 10A)
Half of set current
(max. 5A)
Half of set current
(max. 5A)
Half of set current
(max. 5A)
Equalization 16V/5A max 60mins 32V/2.5A max 60mins 48V/2.5A max 60mins 64V/2.5A max 60mins
Ripple & Noise (p-p) 100mV
Optimal Efficiency 85%
Display Voltmeter; Ammeter; 6 LEDS indicate attery types; DC supply or charger mode and
equalization ON/ OFF
Protection System Over Temperature Protection
Output Over Voltage Protection
Reverse Polarities Protection
Output Short Circuit Protection
Spark Free connection
Cooling Method Thermostatically Controlled Varia le Speed Fan (0-full speed)
Operation
Temperature
-10ºC to 50ºC (Maximum output up to 40°C)
Approval CE
Dimension (LxWxH) 395x234x91 mm
Weight 4.7kg
* All values are ased on the Standard am ient Temperature 25°C and Pressure 0.1Mpa.
* SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
P. 13