Power Max BOONDOCKER PM3B Maintenance and service guide

SAFETY ALERT
FOR YOUR SAFETY, READ ALL INSTRUCTIONS BEFORE INSTALLATION AND OPERATION.
INSTALLER: Provide these instructions to the end user or consumer.
CONSUMER: Keep these instructions for future reference.
WARNING –Avoid Possible Injury or Death
120 VAC is present. This Converter/Charger is designed to convert 120 VAC to 12 VDC. It also provides low voltage
power for charging on-board 12 VDC batteries. The Converter/Charger is a “switch mode” type and is designed to be
maintenance-free with no user serviceable components. The Converter/Charger power output is “current limiting” by
design.
WARNING –Avoid Personal Injury or Product Damage
NEVER store electrical devices in compartments where flammable liquids (such as gasoline) exist.
DO NOT mount/install unit in compartments designed for storage of batteries of flammable liquids.
DISCONNECT DC POWER. Disconnect the battery POS (+) wire at the battery end before connecting this Converter/Charger
to any vehicle/device wiring.
LOCATION. The mounting location may be on any interior (out of direct weather) surface. Location chosen must be accessible
after installation. When mounted inside a cabinet, the cabinet must be large enough to allow dissipation of heated air. Make
sure that there is a minimum of 1” (one inch) free air space at each end of the unit so that cooling air can move through the unit
properly. AVOID foreign contaminants such as dirt, metal particles or moisture.
MOUNTING. Flanges with holes are provided for ease of mounting using standard fasteners. Confirm that the surface that the
converter is mounted to is solid and will hold the weight (6 lbs) during vehicle operation.
ELECTRICAL REQUIREMENTS. A 120 VAC receptacle needs to be located within 36 inches of the Converter/Charger to
supply power. Electrical consideration should also be given to mounting near the locations of the batteries and the 12-volt DC
distribution panel.
AC to DC
CONVERTER/CHARGER
PM3B and PM3BS Models
35, 45, 60, 75, 80 and 100 Amp
3 Stage Charging
Installation & Maintenance

ELECTRICAL CONNECTIONS. Be sure to tighten all connections securely. A loose connection can quickly cause terminals
and wires to overheat. Review unit labels for recommended terminal torque values.
WARNING –Avoid Possible Injury or Death
120 VAC Connection –First confirm that the 120 VAC power source AC circuit breaker(s) are in the off position. DO NOT
turn-on AC circuit breakers until installation is complete.
Using an 8 AWG minimum size copper wire, attach from the vehicle/device chassis to the Converter/Charger Bonding Lug.
Using the attached power cord on the Converter/Charger, connect firmly to the 120 VAC receptacle.

12 VDC Wiring–It is important to use the correct wire gauge. Use a minimum of 8 AWG size copper wire.
The terminal marked +or POS is for the RV 12 VDC positive connection.
The terminal marked –or NEG is for the RV 12 VDC negative connection.
The 12 VDC output wiring does not require over-current protection because the Converter/ Charger limits current output.
However, all electrical connections need to comply with the appropriate NEC code.
3 STAGE CHARGING DESCRIPTIONS.
1. A fast charge (14.6 VDC Max) to bring a good, drained battery back up to full voltage rapidly ("Boost"). 2. A standard charge
(13.6 VDC Nominal) to bring the battery up to a full charge at a safe rate to prolong the life of the battery and provide power to
run 12V lighting and appliances in the vehicle/device ("Normal"). 3. A trickle/float charge (13.2 VDC) to keep the battery fresh
during times of load inactivity ("Storage"). The charger automatically changes modes to accommodate changes in conditions.
The chart below is for reference only.
TEST. First, disconnect all loads and battery on the Converter/Charger by removing all 12 VDC connections from + or POS .
Second, attach a multimeter instrument between the positive and negative terminals of the Converter/Charger. Then energize
the 120 VAC converter circuit. Test for proper output power using the multimeter. Measure the output voltage from the positive
and negative terminals. The voltage should read 13.6 +/- 0.2 VDC. Add 12 VDC load connections to about 2/3 of the rated
capacity of the converter. Recheck the voltage, which should remain approximately the same as at no load.
BATTERY. With the 120 VAC disconnected, reconnect the + or POS positive terminal to a known good battery. With the
converter 120 VAC energized, measure the voltage at the converter and at the battery. The voltage should be about the same
in both locations. As with any battery it is important that the fluid level be checked on a regular basis. When continuously
connected to any charging source all batteries will “Gas” and lose some fluid.
WARNING –Avoid Personal Injury / Product Damage
HI-POT TESTING. (Vehicle/device Manufacturing Facilities Only) DO NOT Hi-Pot DC wiring with the Converter/Charger
connected to the vehicle/device wiring in order to prevent serious injury and/or damage.
14.6 V
13.6 V
13.2 V

TROUBLESHOOTING
NOTE: Before removing and replacing the Converter/charger, perform the following checks:
a. Disconnect the AC power from the vehicle/device.
b. Disconnect the wiring and Battery from the Converter Positive + output terminal.
c. Re-connect the AC power to energize the Converter.
d. Using a voltmeter, measure the voltage at the Converter –and + Output terminals.
> The Converter is OK if the voltage reading is between 13 VDC and 14 VDC (typically 13.6 VDC).
> Otherwise check the table below:
CONDITION
POSSIBLE CAUSE
No 12 VDC output
120 VAC not connected to coach or the coach AC circuit breaker is in the off position.
Reversed battery fuses blown. (Battery wiring connections are reversed),
Severe overload or shorted load. Remove all loads and retest per above instructions.
Converter/Charger internal failure.
Converter cycles On & Off
Fan air flow is inadequate or blocked. (1” minimum free air space at each end required)
Converter/Charger internal failure.
Reversed Battery fuses blown
Battery wiring connections are reversed.
Defective battery, possible bad cells.
12 VDC output is too low
Attached load exceeds rating of the Converter/Charger.
Defective battery, possible bad cells.
Converter/Charger internal failure.
„Reversed-Battery‟ Fuses
Chassis Bonding Lug
12 VDC Output Terminals
AIR FLOW FAN
(on back-side)
.
.
.
.
Blows air out of
front grill vents.

THREE YEAR LIMITED WARRANTY
Limited Warranty and Remedy: Fieldstone Products (“Supplier”) warrants products it sells against faulty
workmanship or the use of defective materials and that such product will conform to published specifications,
drawings and other descriptions for a period of three years.
This warranty is the only warranty made by Supplier and is in lieu of all other warranties, express or implied,
except as to title, and can be amended only by a written instrument signed by an officer of Supplier.
The liability of Supplier under this warranty is limited solely to replacing, repairing or, at Supplier's discretion,
issuing credit for any devices which are returned by Buyer during the schedule period, provided that (a)
Supplier is promptly notified in writing upon discovery of any defect by Buyer with a detailed explanation of any
alleged deficiencies; (b) the defective product is returned to Supplier, transportation charges prepaid by Buyer;
and (c) Supplier's examination of such product discloses to its satisfaction that such defect was not caused by
misuse, neglect, improper installation, repair, alteration or accident. In no event shall Supplier be liable to
Buyer for loss of profits, loss of use, or damages of any kind based upon a claim for breach of warranty.
GENERAL DISCLAIMER
In accordance with our policy of continuous product improvement, Supplier reserves the right to make changes
or improvements to the products and specifications at any time without prior notice. Prices are also subject to
change without notice.
Supplier makes every effort to ensure information provided in our technical literature is accurate and reliable.
We cannot, however, assume responsibility for inadvertent errors, inaccuracies, omissions or subsequent
changes. We assume no responsibility for the use of this information, and any and all such use of this
information shall be entirely at the user's own risk. No patent rights or licenses applicable to any of the
products of Supplier‟s intellectual property described herein are granted to any third party, either directly or by
implication, or any other means. Furthermore, despite efforts to ensure otherwise, we make no representation
that the information and/or circuitry described herein is free of infringement on any intellectual property rights
or any other rights of third parties.
Fieldstone Products PMB 103 • 11161 E SR 70 STE 110 • Lakewood Ranch, FL 34202
Phone: [phone] • Fax: [phone]
www.powermaxconverters.com