Manzanita Micro PFC-20 User manual

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PFC-20, PFC-30 &
PFC-40 Charger
Owner’s Manual
Rev 3.1
©2013 Manzanita Micro LLC The information date is: 06/07/2013
Manzanita Micro reserves the right to alter product offerings and specifications at any time without notice, and is not
responsible for typographical or graphical errors that may appear in this document.

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CONTENTS
IMPORTANT SAFETY WARNINGS.. 3
IMPORTANT BATTERY SAFETY INFORMATION 4
GENERAL OVERVIEW 5
KEY FEATURES LIST. 6
DIMENSIONS AND SPECIFICATIONS 7
CHARGER OPERATION. 8
- P oto of C arger Face Wit Callouts. 8
- Volts Trim ~ Adjusting t e Peak C arging Voltage Limit.. 9-10
- Volts Trim using optional Digipot Pus -Button Adjuster.. 10-11
- Reg Bus ~ Basic Info.......... 12
- Descriptions of Panel LED Indicators.....12-13
- Dip Switc es.. 14
WIRING YOUR MANZANITA MICRO CHARGER.. 15
- Connecting t e C arger to t e Battery Pack 15
- Connecting t e C arger to t e Wall 16
- PFC20 Wiring. 17
- PFC30 Wiring. 17
- PFC40 Wiring. 18
- Running Your PFC C arger on DC instead of AC... 18
- 120V Standard Adapter Drawing for PFC20 & PFC30. 19
- 120V Standard Adapter Drawing for PFC40.. 20
- Reg Bus Wiring & Pin-out Info.. 21
- Reg Bus Cable Construction.....22-24
- New 8A Control Board Additional Features...24-25
- AC Line Power Meter Options....26
- Optional Rear Control Port for Current Control or J1772...27
- Remote Current Knob............................................................27-29
- Older C arger S eet Metal Front Image...............................29
- Auto Restart Set Point Adjustment ..................................30-32
CONTACTING MANZANITA MICRO.......................32

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READ THIS FIRST!
ADDITIONAL NOTES AND PRODUCT MANUALS AVAILABLE AT: www.manzanitamicro.com
CAUTION: Your PFC-C arger uses Hig Voltage DC and AC electricity.
T e c argers ave been designed to be adaptable for use wit many different battery types and
voltages. It is t e responsibility of t e end user to properly set up t e c arger making necessary
adjustments so t at it can work wit t eir unique system. Wit suc flexibility, t e c arger is intended
to be able to be configured for use in various experimental applications and Manzanita Micro LLC and
its employees, contractors and affiliates cannot be responsible for any damages due to any Manzanita
Micro product t at as been set up by t e end user. T ere are too many variables out of Manzanita
Micro's control. It is entirely t e responsibility of t e end user to make sure t at t ey are competent to
work wit potentially let al voltages and t at t ey ave a solid understanding of ow to safely integrate
t e Manzanita Micro product(s) into t eir application.
T e information contained in t is warning and in t e product manuals is intended to be used as a guide
to better familiarize oneself wit t e product(s) but Manzanita Micro as no control over ow t e
information will be used or not used and cannot possibly foresee all possible configurations t at a user
may come up wit .
1. Do not work on t e PFC-C arger or attempt to use one if you are not qualified
2. Observe t e owner’s manual procedures and cautions
3. Avoid working on an electric ve icle w ile it’s c arging
4. ALWAYS assume t at ig voltage is present
5.
Use electrical tape or anot er suitable insulators to cover all exposed ig voltage connection
points. Use properly insulated tools to reduce t e likeli ood of t e tool completing a current pat
6. DO NOT USE A CONDUCTIVE METAL SCREW DRIVER TO ADJUST THE VOLTS TRIM ON YOUR
CHARGER!
7. W en using a Manzanita Micro BMS wit older c arger models t e regbus GND return line is NOT
ISOLATED FROM MAIN BATTERY PACK NEGATIVE! Never touc or create a pat from t e regbus
conductors to any battery in t e pack or serious s ock could occur!
8. Disconnect all ot er non-isolated c argers from t e battery pack and from line current
9. Make sure t ere is NO PATH TO GROUND or t e ve icle c assis from any portion of t e main
battery pack.
10. Make sure t e polarity is correct BEFORE you ook t e battery pack to t e c arger cable.
11. Make sure t e area around and above t e workplace is clean and dry
12. Do not compress or set eavy objects on t e c arger. Deforming t e case can result in s orting t e
internal circuit boards to t e case.
13. DO NOT operate t is c arger unloaded! A battery pack must always be plugged in to t e DC output
plug from t e c arger if it is turned on!
FAILURE TO HEED THESE WARNINGS AS WELL AS THE BATTERY WARNINGS ON THE BACK OF THIS
SHEET MAY RESULT IN PHYSICAL INJURY, DEATH, OR DAMAGE TO YOUR CHARGER, BMS OR
OTHER EQUIPMENT WHICH WILL NOT BE COVERED UNDER YOUR WARRANTY.
IT IS RISKY TO PLUG ANY BATTERY CHARGER INCLUDING MANZANITA MICRO CHARGERS INTO
GENERATORS. MANY GENERATORS ESPECIALLY THE LESS EXPENSIVE GENSETS DO NOT HAVE A
CLEAN, WELL REGULATED, PREDICTABLE OUTPUT AND THEY CAN CREATE HIGH VOLTAGE SPIKES
WHICH CAN DAMAGE COMPONENTS IN THE CHARGER. SOME CUSTOMERS HAVE HAD SUCCESS
WITH HIGH END PURE SINE WAVE COMPUTER GRADE GENERATORS BUT MANZANITA MICRO
CANNOT RECOMMEND A SPECIFIC MODEL AT THIS TIME AND CANNOT BE RESPONSIBLE FOR ANY
DAMAGE DUE TO GENERATORS OR OTHER POWER SOURCE PROBLEMS.

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BATTERY NOTES!
CAUTION: Your PFC-C arger can output over 400 volts DC and many t ousands of watts of electrical
power! It is imperative t at t e end user ave a clear understanding of ow to safely c arge t eir
particular battery!
Manzanita Micro sells very flexible c arging systems t at can be used wit almost any type of battery.
Manzanita Micro c argers are used in all sorts of applications. Manzanita Micro LLC cannot be eld
responsible for any problems arising from t e improper use of t e c arger or BMS wit a battery pack
or ot er storage device.
FAILURE TO OPERATE BATTERIES OR OTHER ENERGY STORAGE DEVICES WITHIN THEIR SAFE
DESIGN PARAMETERS CAN RESULT IN CATASTROPHIC FAILURES INCLUDING BUT NOT LIMITED TO
FIRE, EXPLOSION, TOXIC FUMES, EXCESSIVE HEAT, THE RELEASE OF CAUSTIC OR POISONOUS
MATERIALS, PHYSICAL DEFORMATION AND VARIOUS OTHER POTENTIALLY LETHAL SITUATIONS.
ALWAYS WEAR EYE PROTECTION AND OTHER PROPER PERSONAL PROTECTIVE EQUIPMENT WHEN
WORKING AROUND BATTERIES. UNDERSTAND THE SAFE HANDLING INSTRUCTIONS AND
IMPORTANT SPECIFICATIONS OF YOUR PARTICULAR BATTERY PACK OR ENERGY STORAGE
DEVICE! IF EVER IN DOUBT, CONTACT THE BATTERY MANUFACTURER!
NEVER ALLOW MORE THAN ONE PERSON TO WORK ON THE SAME HIGH VOLTAGE SYSTEM OR
BATTERY PACK AT THE SAME TIME. IF TWO OR MORE PEOPLE ARE TOUCHING PARTS OF THE
SYSTEM IT IS EASIER TO COMPLETE A CIRCUIT AND CAUSE ELECTROCUTION. WHILE MULTIPLE
PEOPLE SHOULD NEVER WORK ON THE SAME SYSTEM, IT IS ADVISABLE TO HAVE MORE THAN ONE
PERSON NEAR BY WHENEVER ONE PERSON IS WORKING WITH HIGH VOLTAGE.
NEVER TOUCH ANYBODY WHILE THEY ARE WORKING ON A HIGH VOLTAGE SYSTEM OR BATTERY
PACK! IF SOMEONE IS GETTING SHOCKED AND CANNOT LET GO OF THE ELECTRICAL SOURCE, THE
EXTRA PERSON CAN SAFELY DISCONNECT THE ELECTRICAL SUPPLY AND/OR GET HELP. IF IT IS
NOT POSSIBLE TO DISCONNECT THE SUPPLY, AND IF PROPERLY INSULATED EQUIPMENT IS
AVAILABLE THEN THE EXTRA PERSON MAY USE A DEVICE SUCH AS AN INSULATED HUMAN HOOK
TO PULL THE PERSON BEING SHOCKED AWAY FROM THE ELECTRICITY. NEVER EVER TOUCH
SOMEONE WHO IS BEING SHOCKED!
Manzanita Micro c argers are very powerful. Do not exceed t e safe c arging rates as specified by your
particular battery manufacturer!
Manzanita Micro c argers are capable of outputting any c arging voltage from 12 to 450 volts DC. It is
up to t e end user to understand t e safe voltage range for t eir particular battery, cell, battery pack or
ot er energy storage device. Do not exceed t e peak c arging voltage given by t e battery
manufacturer. Carefully read t e Manzanita Micro Owner’s Manual(s) for your particular product(s). For
c argers, it is essential to understand ow to properly set t e peak c arging limit using t e volts trim
potentiometer or optional digipot. For BMS (Battery Management Systems) it is imperative t at t e user
makes sure t at t e BMS is properly set to matc t e safe and appropriate parameters for t eir
particular make and model of battery and t at t e BMS can communicate wit t e c arger.
Ask t e battery manufacturer for all parameters on ow to safely c arge t eir batteries and do not use
any c arger or BMS if you cannot properly tune t e equipment to meet t ose specifications.

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PFC-20/30/40 SERIES
BATTERY CHARGER
MANUAL REV 3.1
General Overview
The Manzanita Micro FC chargers are a unique group of powerful, efficient battery
chargers. The chargers will operate on any voltage from 100 up to 240 volts AC.
The chargers can be set to run automatically when plugged in, yet they also have far
more user adjustable functions than other electric vehicle chargers. Every model is
user adjustable to charge batteries from 12 to 450 Volts DC. All the chargers are
power factor corrected and are available with enhanced options such as AC input
power displays. With so much flexibility and models from 20 to 75amps, your FC
charger may be the last charger you ever need to buy.
Speed and Efficiency
The essential ingredient for fast recharge times is to deliver as much power to the
battery as practical. The key to polite opportunity charging is to be able to share
outlets with other equipment and make efficient use of limited current. The
Manzanita Micro FC line of chargers has an adjustable current throttle knob to
allow the chargers to be turned down to operate on very limited power sources.
Efficiency is usually well over 90% and power factor is typically better than 0.9.
W at does t e PFC mean?
FC stands for ower Factor Corrected. The Manzanita Micro FC chargers have
special circuitry to make sure the voltage and current are drawn in unity, so that the
apparent power (Volt-amps) is very close to the real power (Watts). This ratio of
apparent power to real power is the power factor and it is expressed as a number

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between 0 and 1. The closer to 1 the better. Manzanita Micro FC chargers
generally have a very high power factor number which means less wasted energy.
PFC-20/30/40 SERIES
CHARGER FEATURES
•ower Factor Corrected
•Every charger easily runs on 110/120V and 220/240V
•Easy ‘Amps’ adjustment knob allows users to quick-tune the charger to pull
maximum amps from the incoming power source
•Optional current control port for remote amperage control or J1772 control
•User adjustable peak charge voltage allows users to adapt charger to any
battery voltage from 12 to 450 volts
•Up to 9,600 watts of power from a unit that weighs less than 20 lbs (9kg) and is
about the size of a shoe box
•Reg bus port for easy integration with Manzanita Micro BMS (also compatible
with other Battery Management Systems)
•Self regulating thermal protection
•Active variable speed fan cooling
•Water cooling option
•Input line voltage, line current, wattage and power factor meter option
•Adjustable absorption phase (end of charge) timer function
•Ability to enable auto restart mode
•Ability to enable timed charging mode
•Standard FC-20 and FC40HM ( HEV) models can run on both AC or DC
voltage (* Buck enhanced models can also run on DC if modified)
•Now with a latched timer mode
•Float charge option possible with new 8A control board

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•Chargers with 8A or newer control board have 2 additional peak voltage set
points and one additional amperage set point which can be enabled via the
4pin RJ connection on the blue face plate
Dimensions, Specifications and Mounting
The FC-20, FC-30 and FC-40 chargers weigh approximately 18 pounds (8.2 kg)
The maximum outermost dimensions including foot flanges and protrusions are
approximately: 14” L x 10.5” W x 5.75” H (358mm x 264mm x 145mm)
Input Voltage Range : 100 to 240VAC 40-80Hz computer grade pure sine wave.
Output Voltage Range : 12 to 450VDC ( +/- 1 volt )
Operating Temp Range : -20° F to +120° F ( -28.8° C to +48.8° C )
ower Consumption : Up to 9.6kW ~ FC40 / 7.2kW ~ FC30 / 4.8kW ~ FC20
The 20, 30 or 40 nomenclature is indicative of how many amps that charger is rated
to draw from the AC input power line. Unlike some other chargers, this is the rated
continuous load and all units are thoroughly tested to their rated limits before leaving
Manzanita Micro. An optional multifunction panel mount meter is available which
displays the amount of current (amps) that the charger is drawing off the AC line as
well as the AC Line voltage, total wattage and power factor. This information allows
for fine tuning to get maximum power from wall outlets without tripping breakers and
it also provides a way to estimate charging time based on the watts being used.
The charger can be mounted in any orientation as long as it has adequate airflow
and is protected from sucking in moisture and debris. All chargers are designed to
automatically cut back current when they exceed their temperature limits. If the

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yellow limits light starts blinking and the charger's current cuts back, it is likely more
airflow is needed. The fans push the air out through the front of the charger,
therefore, mounting the unit such that the control face is pointing upward is probably
the most efficient since heat rises.
C arger Operation
figure 02. harger Layout Since November 2012
(see final section for older chargers)
Turning t e C arger On and Off
There is an ON/OFF Breaker to the right of the front exhaust port (or coolant fittings
on liquid cooled models). This breaker is the main switch to turn the charger on or
off. If ever there is a concern while charging first shut off this breaker switch.
NOTICE! DO NOT unplug the gray SB-50 Anderson connectors (DC line) from
your charger while it is charging! If the battery pack is disconnected while the
charger is putting out power the charger can be damaged. Failure to eed t ese
warnings may result in significant internal damage to t e c arger w ic is not
covered under your warranty!

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User Control Panel
The user interface panel is the long blue panel with white or yellow text near the top
of the FC charger. It is important to familiarize yourself with the LED indicators,
the VOLTS TRIM potentiometer (if so equipped) and the adjustable AM S knob.
Below are explanations of each feature in order from left to right. Refer to figure 02
or the 8A Control Board section (figure 13) for specific locations.
“VOLTS TRIM”
This critical adjustment potentiometer controls the peak DC voltage ceiling that the
charger will allow the batteries to reach before limiting the current. Unless specified
otherwise, the DC output voltage limit is specifically calibrated and set by Manzanita
Micro to 48 volts. In the event that adjustment is desired, please follow the
instructions below. Starting in 2010, a special insulated screw driver for adjusting the
volts trim is shipped with each new Manzanita FC charger.
ATTENTION! If your charger has an optional Digipot push-button device for peak
voltage adjustment please see the section immediately after this one titled: Optional
Digipot eak Voltage Adjustment.
NOTICE! Always use an appropriately sized insulated screw driver when adjusting
the voltage trim potentiometer. Suitable drivers are available for purchase from
Manzanita Micro or other electronics components manufacturers. (Mouser part #:
594-8T000, Vishay/Spectrol Adjust Tool, www.mouser.com)
figure 03. Adjustment Tool # 008T000
NOTE: If the battery pack is not heated for any reason such as outdoors in a cold
climate, the peak charging voltage threshold may need to be raised in order to
assure a complete charge. This is especially true for lead acid batteries. Many users
turn the volts trim to the absolute maximum safe level for the batteries during the
winter and then back down to normal during the summer months. Always consult
your battery manufacturer for information on the peak “fully charged” voltage
specifications and how they might change based on temperature.
NOTE: The peak voltage regulation set point on a Manzanita Micro charger is
accurate to within 5 volts or less. Follow the “Volts Trim Calibration” instructions on
the next page and make the initial adjustment with the amps knob completely down
so that no current is flowing. Gradually turn up the amps knob and nudge the volts
trim potentiometer up accordingly. Use caution on the first charge cycle and make
sure to check that the point at which the charger volts trim (peak voltage) limit is
reached is really the correct voltage for your specific batteries.
VOLTS TRIM CALIBRATION WITH ORIGINAL ROTARY OTENTIOMETER:

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Final tuning is best accomplished when the battery pack is fully charged. The lower
the state of charge, the more the user will need to monitor and adjust the unit during
the first charge cycle.
1. Turn the amps knob all the way down (full counterclockwise).
2. Make sure the charger is plugged into the battery pack and that there are no open breakers or
open fuses in the DC battery circuit.
3. With the charger’s AC breaker switch in the OFF position, plug the charger into the AC power
outlet.
4. Now turn ON the charger’s AC breaker switch. The fans should come on.
5. Using an appropriate insulated screw driver, stick it into the VOLTS TRIM access hole (see
figure 04) and turn the internal adjustment potentiometer until you find the threshold where the
yellow LIMITS LED changes state. If the yellow LED is off, turn the trim pot counterclockwise
to get it to turn on. If the yellow LED is on, turn the trim pot clockwise to get it to go off. Once
you find the threshold where the LED changes states, the cutoff voltage is set to the actual
battery voltage and the charger will not charge the pack above this voltage. Therefore, when
you are ready to charge you will need to turn the trim pot clockwise to raise this voltage
ceiling. Turn the AM S knob up until you can put the amount of amps you want into the
battery pack while not letting the batteries go over their peak voltage limit according to the
battery manufacturer’s data. (Note: This pot can be turned many times)
When the battery pack voltage hits the peak limit the yellow LIMITS LED will come
on along with the flashing blue TIMER LED and the charger cuts back.
figure 04. VOLTS TRIM Adjustment
O TIONAL DIGI OT EAK VOLTAGE ADJUSTMENT

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This critical push-button potentiometer controls the peak DC voltage ceiling that the
charger will allow the batteries to reach before limiting the current. Unless specified
otherwise, the voltage limit is set by Manzanita Micro to 48 volts. In the event that
adjustment is desired, please refer to Figure 05 and follow the instructions on the
next page. When the battery pack voltage hits the peak limit the yellow LIMITS LED
will come on along with the flashing blue TIMER LED and the charger cuts back.
Figure 05 : Optional Digipot Peak Voltage Adjustment
IMPORTANT WARNING!
It is not recommended to change the digipot when the charger is moving power. Simply pressing even one of
the buttons on the digipot can drastically and immediately change the charger's peak output voltage! It is the full
responsibility of the end-user to make sure that the digipot is set to a value that is safe for the energy source
that the charger's output power is connected to! Furthermore, the numbers on the digipot may not be exactly
accurate down to the volt so users should check at the end of the first charge with a calibrated voltmeter to
make sure the yellow limits light comes on and the FC charger is not exceeding the maximum safe voltage
level for the customer's given scenario.
The optional digipot makes it very easy to adjust the peak voltage set point, therefore it is up to the user to
check and make sure that no person or thing changed the voltage setting to a level inappropriate for the battery
pack being charged. The digipot displays the approximate peak voltage set point level reading from left to right.
So in Figure 05, the example photo shows the digipot set at 190 meaning that the charger's maximum output
voltage should be about 190 volts DC.
The digipot display is similar to an odometer in a vehicle. ressing the “+” button above a numeric digit will
increase that digit by one whole number until the number “9” is reached at which point if it is pressed again it will
drop back to “0”
ressing the “-” button below a numeric digit will decrease that digit by one whole number until “0” (zero) is
reached at which point if it is pressed again, it will jump up to “9”.
WARNING! Be very careful especially with the left-most digipot buttons that it never get's accidentally set to a
high number like “9” because that would make the charger try and output maximum voltage up to 900+ volts
which could damage the battery pack! The internal limit on the charger should be set at 450VDC and so even if
it doesn't put out 900 volts, setting the digipot to display any number greater than 450 should make it
automatically output at least up to 450VDC!

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When the battery pack voltage hits the peak limit the yellow LIMITS LED will come on along with the flashing
blue TIMER LED and the charger will cut back.
NOTE: If the battery pack is not heated for any reason such as outdoors in a cold climate, the peak charging
voltage threshold will likely need to be raised in order to assure a complete charge. This is especially true for
lead acid batteries. Many users turn the volts trim to the absolute maximum safe level for the batteries during
the winter and then back down to normal during the summer months. Always consult your battery manufacturer
for information on the peak “fully charged” voltage specifications and how they change based on temperature.
Use caution on the first charge cycle and make sure to check that the point at which the charger volts trim limit
is reached is really the correct voltage for your specific batteries.
“REG BUS”
This is the 6 pin RJ jack where the BMS communication line plugs into the charger.
This port allows the individual battery regulators to communicate with the charger.
For more information on the specific reg bus pins refer to the “Reg Bus Wiring”
section later in this manual.
NOTICE! If your vehicle is equipped with a Manzanita Micro Battery Management
System, ensure that the reg bus data cable is fully plugged into the charger
whenever the vehicle is charging. The communication data cables are hooked to the
regulators in a daisy chain fashion. Make sure that each of the smaller data cables
are all plugged in where they should be before charging. If t ere is an unplugged
portion of t e reg bus, t e c arger cannot communicate wit t e regs and t is
could cause overc arging and potential fire! The RJ connectors are similar to
phone cord connectors and they are designed to snap into place and stay
connected. If a cable is disconnected insure that it is fully reconnected. An audible
*click* should be heard when the RJ plug is fully inserted and it should not be able to
be pulled out without first pinching the small plastic tab underneath the plug. For
more information on reg bus cables refer to the “Reg Bus Wiring” section later in this
manual.
“ OWER” - Green LED
The bright green OWER LED indicates when the charger is on. Input power is
being supplied to the unit and the main breaker is in the ON position.
“WARN” - Red LED
The red WARN LED should blink briefly when the charger is first powered up and
then remain off for the duration of the charge. If this indicator stays on, turn down
the AM S knob immediately, turn off the charger’s breaker switch and consult
Manzanita Micro or a qualified service technician. This LED could indicate an over
voltage or over temperature condition. It could also be indicative of an open circuit
condition in the pack. Turn down the AM S knob and check to make sure there is
no open circuit condition in the battery pack. Check the gray SB-50 Anderson
connector to insure that it is tightly connected and look for other disconnected
battery cables. If the charger will not work and the circuit is complete, contact
Manzanita Micro.
NOTICE! DO NOT let the charger try to put current into the battery pack if there is
an open circuit condition anywhere in the circuit. Never unplug the gray SB-50

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Anderson connectors (DC line) from your charger while it is charging! If the battery
pack is disconnected while the charger is putting out power the charger can be
damaged. Failure to eed t ese warnings may result in significant internal
damage to t e c arger w ic is not covered under your warranty!
“AM S” Knob
The AM S knob allows the user to adjust how much current the charger will move.
If the vehicle is always plugged in to the same circuit this shouldn’t need any
adjusting but if the user were to have it set at 35 amps and then plug into a 15 amp
110V outlet it will quickly open a circuit breaker or fuse on the AC line. The vehicle
operator may wish to adjust this knob when the charger is plugged in to a public
outlet especially if there is no easy access to the electrical panel for that circuit.
Additionally, the user might need to turn down the charger if there are other loads on
the branch circuit (example: A stereo and a computer are running on the same 15
amp circuit). If using a charger equipped with the panel mount meter, the user can
check the digital current meter on the front of the FC unit and see exactly how
many amps the charger is drawing off of the AC line.
“LIMITS” - Yellow LED
The yellow LIMITS LED indicates that the charger has reached its peak voltage limit.
This should happen only at the end of the charge cycle when all the batteries are
fully charged. The LIMITS indicator should be accompanied by the blinking blue
TIMER LED which indicates that the charger is in current cutback mode and the
timer is counting down to the end of charge.
If the yellow LIMITS LED is blinking, then it is indicating that there is an over
temperature condition and the charger is in thermal cutback mode.
NOTE: When using regulators, the blue TIMER LED will often come on before the
LIMITS LED because the battery regulators let the charger know when the batteries
are getting full before the voltage limit is reached. If the LIMITS light is coming on
frequently or before most of the regs are blinking, this could be indicative of a few
batteries whose voltages are getting too high. It could also mean that someone has
improperly adjusted the VOLTS TRIM. Consult your battery regulator user’s manual
or recalibrate the VOLTS TRIM setting on the charger.
“TIMER” - Blue LED
The blue TIMER LED indicates that the charge is complete or near completion. If it
is flashing it means that charging is almost finished and the charger is backing off
the current and counting down the timeout timer. When the blue LED is steady, it
means that the timeout timer has ended and the charger has finished charging the
pack. At this point the charger should be putting out no power and drawing less than
an amp off the input line.

14
“TIMER ADJ”
This stands for timer adjustment. This is a small 16 position rotary switch which
allows the user to adjust the amount of time that the charger takes in constant
voltage mode, while cutting back current at the end of a charge cycle before it shuts
off completely. If the switch is at ‘0’ then the timer will time out instantly - do not use
this setting. (‘0’ is the 3-o-clock position when viewed from the front). If the switch is
at ‘3:00’ it will go for 15 minutes before completely cutting back power. Each
additional tick after ‘1’ adds 10 more minutes to the charge cutback time. Turning
the switch clockwise all the way around to the 2:30 position will give the maximum
amount of time.
To reset the timer after it has started turn off the
power to the charger and then turn the power on
again.
“DI SWITCHES”
The red and white dip switch module is on the upper right end of the charger. This is
a bank of 8 switches and they are numbered starting with #1 on the far right.
NOTICE! Adjusting these switches can cause the charger to perform in an
undesirable manner! lease be sure you understand these switch features before
changing them. ull switches down to turn them on. The image above shows the
factory preset positions.
NEVER HANGE DIP SWIT H #4! IT MUST REMAIN ON!
Dip Switch Guide:
1. Engages timer at peak voltage limit set point. This switch should be ON.
If the pack drops below the peak voltage limit, the timer will turn off again.
2. Starts timer as soon as the charger is turned on. This can be used for timed
charging. This switch should be OFF.
3. Starts timer when the reg bus commands. This switch should be ON.
If the reg bus stops sending the signal, the timer will turn off again.
4. Future feature switch. THIS SWITCH M ST ALWAYS BE ON!
5. Future low battery detection feature. This switch should be OFF.
6. AGM battery equalization. When using Mk2 series battery regulators, this will
allow the batteries to climb to a slightly higher voltage for equalization at the end
of charge. It also commands the yellow LEDs on each reg to turn on. This
switch should be OFF.
7. When the high voltage limit is set the charger stops moving power immediately.
The timer is not used at all when in this mode. This should be OFF.
8. Auto restart function. This allows the charger to restart charging when the battery
pack reaches the low voltage set point. This switch should be OFF unless using

15
the auto restart feature which is set by VR6 behind the front faceplate (see figure
13).
NOTE: Dip switch #6 can be useful if you have a Manzanita Micro BMS because
you can momentarily switch it on and the yellow lights on all the regs should come
on. If any do not illuminate, you can use this feature to narrow down which regs are
not communicating with the charger or find bad reg bus communication cables.
NOTE: In mid 2010, a new 4 pin RJ receptacle was added to the front of the charger
allowing for activation of various extra preset voltage and current levels. For more
information please refer to the 8A Control Board section at the end of this manual.
Wiring your Manzanita Micro C arger
Your FC-20, 30 or 40 charger has two main power cables coming out of the rear of
the case (see final section for older models) The lower cable is for the incoming
power (usually AC from a wall outlet) and the top cable is the charger’s DC output.
Connecting t e C arger to t e Battery Pack
The DC output cable has a gray SB-50 Anderson connector on it. This SB-50 is
quite common on EV battery chargers and we recommend that you leave this plug
on the cord. The SB-50 connector has clearly marked positive and negative sides.
Of the three DC wires coming out of the charger white is positive, black is negative
and green is an optional vehicle chassis ground connection. Measure the distance
from your most positive battery terminal to your FC charger’s SB-50 connector. Cut
a #6 AWG or thicker cable to the appropriate length and solder or crimp the
appropriate size SB-50 contact onto one end of the cable. It is recommended that
you use bright orange cable with a good insulation and voltage rating in excess of
your fully charged pack voltage. (Bright orange Carol brand Super Vu-Tron welding
cable is an excellent solution.) lace red heat shrink or red electrical tape around
the cable near each end to clearly designate it as the positive cable and then using
a matching gray SB-50 connector, push the SB-50 contact end of the positive cable
into the positive side of the SB-50 until it clicks and locks in place.
Measure the distance from your most negative battery terminal to your FC
charger’s SB-50 connector. Follow the same procedure as for the positive side only
use black heat shrink or black electrical tape around the cable near each end to
clearly designate this as the negative cable. ush the SB-50 pin end of this negative
cable into the negative side of the SB-50 until it clicks and locks in place.

16
figure 07: D Battery Side User-Built Example Power able
Now you should have a gray SB-50 connector with a positive and negative wire
coming out. (See figure 07) Use the appropriate lug or connector for your battery
terminal and connect it onto the other end of each cable. Connect the positive cable
to the most positive terminal of the battery pack. Connect the negative cable to the
most negative terminal of the battery pack. Double check that the polarity is correct
and then plug the battery pack SB-50 into the DC output SB-50 coming from the
FC charger (see figure 08). Now the charger is connected to the pack and you are
ready to hook up the charger’s input power.

17
figure 08
Connecting t e C arger to t e Wall
Looking at the charger chassis where the big black cables are attached you will see
the letters AC printed next to one of the cables and this is for the incoming power for
the charger. A great feature of the Manzanita Micro FC line of chargers is that
they are capable of operating easily from 110,120, 208, 220, 230 or 240 volts of
single phase AC power. In fact some models can even be run from DC but most
users are plugging them into an AC wall outlet of some sort. Standard FC-30,
FC-40 and other buck enhanced chargers must be modified to run off DC, see the
“Running Your FC Charger on DC instead of AC” section later in this manual.
NOTE: The brass stud in the rear of newer chargers should be connected to the
vehicle chassis to ensure a solid ground connection. This stud can be seen in figure
15 which is toward the end of this manual.
Ohm’s law states that Volts x Amps = Watts of power and there are a certain
number of “Watt Hours” stored in your battery pack and available to power your
electric vehicle. Based on the V*A=Watts equation it is easy to see that more volts
or amps (or both) equates to more total watts which means more electrical power
moving, and thus faster charging.
Your Manzanita Micro FC charger can be powered by any input voltage within the
100-240V range and there are no input voltage adjustment switches to move when
changing between outlets of different voltages. The only thing which may need

18
adjustment on the charger is the big “Amps” knob on the front. Turn this knob up or
down depending on the amperage available from the outlet. With the “Amps” knob
in the most clockwise position a FC-20 can draw up to 20 amps, a FC-30 can
draw up to 30A and a FC-40 can draw up to 40A.
EXAMPLE: A FC-40 plugged into a standard 120V outlet at 15 amps would be
able to draw about 1,800 watts (120x15 = 1,800). The same FC-40 plugged into a
240V outlet at 50 amps could draw up to 40A so that would be about 9,600 watts,
meaning a charge time that is over 5 times faster than in the 120V scenario.
PFC-20 Wiring
The FC-20 is shipped with no connector on the 3-wire AC input cable. To attach
the FC-20’s input cable to a common 110/120V three prong 5-15 or 5-20 plug run
the green (GND) wire to the ground prong, the white wire to the silver screw terminal
of one of the straight prongs and the black (line) wire to the brass screw terminal of
the other straight prong. If you want to connect your FC-20’s input cable to a
220/240V three prong plug like a NEMA 10-30, run the green wire to the ground
prong and then the white and black wires to either of the two hot prongs.
PFC-30 Wiring
The FC-30 is shipped with a NEMA 14-30 on the 4-wire AC input cable. lease
leave this attached and make adapter cords if you intend to change what it plugs
into. To attach the FC-30’s input cable to a common 110/120V three prong 5-15 or
5-20 plug, purchase a 14-30 receptacle and make an adapter exactly as shown in
figure 09. If you wish to make an adapter cord to connect your FC-30’s input cable
to a 220/240V three prong plug (like a NEMA 10-30, 10-40 or 6-50), use a 14-30
receptacle and simply disregard the white wire and the angled neutral prong. Run
the green wire to the ground prong and then the red and black wires to either of the
two hot prongs. Since there is no neutral in the older 3 prong 220/240V plugs simply
disregard the fact that your FC charger has a 4 prong plug on it.
The FC-30 and FC-40 chargers come with a 4 wire AC input cable but do not
ever use the white neutral wire for anything. Even though there is a 4-wire plug on
the unit, t e w ite wire s ould never be connected to anyt ing.
PFC-40 Wiring
The FC-40 is shipped with a NEMA 14-50 on the 4-wire AC input cable. lease
leave this attached and make adapter cords if you intend to change what it plugs in
to. The 14-50 outlet is very common for electric ovens in homes, at RV parks with
50A service and even at some public charging stations.
To attach the FC-40’s input cable to a common 110/120V three prong 5-15 or 5-20
plug purchase a 14-50 receptacle and make an adapter exactly as shown in figure

19
10. If you wish to make an adapter cord to connect your FC-40’s input cable to a
220/240V three prong plug (like a NEMA 10-30, 10-40 or 6-50), use a 14-50
receptacle and simply disregard the white wire and the middle straight neutral prong.
Run the green wire to the ground prong and then the red and black wires to either of
the two hot prongs.
The FC-30 and FC-40 chargers come with a 4 wire AC input cable but do not
ever use the White neutral wire for anything. Even though there is a 4-wire plug on
the unit, t e w ite wire s ould never be connected to anyt ing.
Note: Any Manzanita Micro FC-20, 30 or 40 charger can be plugged into a NEMA
14-50 outlet. The 50 amp rating is just what the outlet is capable of and the charger
will only draw as much as it is designed to use.
Running Your PFC C arger on DC instead of AC
You may have heard that Manzanita Micro chargers can run from both AC and DC
power. This is true under the right circumstances.
NOTICE! The Manzanita Micro chargers were primarily designed to run from an AC
power source. If you are planning to run one on DC power and it is damaged, repair
work will likely NOT BE COVERED UNDER WARRANTY! It s ould be noted t at
t e primary on/off circuit breaker on t e c arger is only AC rated. For t is
reason, we recommend installing an appropriate DC rated breaker or fuse on
t e input side w en powering any Manzanita c arger wit DC.
There are two Manzanita Micro FC charger models which can be run from DC
power without having to make any internal adjustments to the unit. These unique
models are the standard FC-20 and the FC-40HM. Some pre-2011 standard
FC-50 chargers may work as well but check with Manzanita Micro to be sure.
If you are running a charger on DC power, it is advisable to keep the input voltage
between 100 and 390VDC. The lowest voltage that will get the charger to turn on is
about 60VDC. The absolute highest acceptable DC input voltage is 400V. NEVER
EVER EXCEED THE 400VDC MAXIMUM INPUT VOLTAGE!!
NOTE: The buck enhanced chargers including the FC-20B, the standard FC-30
and FC-40 and the FC-50B and FC-75 chargers can be modified to run on DC
by disconnecting the buck sensor unit and adding a jumper over two pins on the
control board. Contact Manzanita Micro for more information if you if you are really
determined to run a buck enhanced charger from a DC power source.

20
figure 09. PF -20/30 Adapter Wiring