Power Max PM15 Maintenance and service guide
ACtoDCConverter/Charger
ACtoDC
CONVERTER/CHARGER
PMmodels15,35,45,55,60,75,85and
100Amp4StageCharging
Installation&Maintenance
SAFETYALERT
FORYOURSAFETY,READALLINSTRUCTIONSBEFOREINSTALLATIONANDOPERATION.
INSTALLER:Providetheseinstructionstotheenduserorconsumer.
CONSUMER:Keeptheseinstructionsforfuturereference.
NOTICE:Productsarenottobeusednorarewarrantedinaerospace,medicalorlifesafetyapplications.
WARNING–AvoidPossibleInjuryorDeath
120VACispresent.ThisConverter/Chargerisdesignedtoconvert120VACto12VDC.Italsoprovideslowvoltage
powerforchargingonboard12VDCbatteries.TheConverter/Chargerisa“switchmode”typeandisdesignedtobe
maintenancefreewithnouserserviceablecomponents.TheConverter/Chargerpoweroutputis“currentlimiting”by
design.
WARNING–AvoidPersonalInjuryorProductDamage
NEVERstoreelectricaldevicesincompartmentswhereflammableliquids(suchasgasoline)exist.
DONOTmount/installunitincompartmentsdesignedforstorageofbatteriesofflammableliquids.
1. DISCONNECTDCPOWER.DisconnectthebatteryPOS(+)wireatthebatteryendbeforeconnectingthisConverter/Charger
toanyvehicle/devicewiring.
2. LOCATION.Themountinglocationmaybeonanyinterior(outofdirectweather)surface.Locationchosenmustbe
accessibleafterinstallation.Whenmountedinsideacabinet,thecabinetmustbelargeenoughtoallowdissipationofheated
air.Makesurethatthereisaminimumof1”(oneinch)freeairspaceateachendoftheunitsothatcoolingaircanmove
throughtheunitproperly.AVOIDforeigncontaminantssuchasdirt,metalparticlesormoisture.
3. MOUNTING.Flangeswithholesareprovidedforeaseofmountingusingstandardfasteners.Confirmthatthesurfacethat
theconverterismountedtoissolidandwillholdtheweight(6lbs)duringvehicleoperation.
4. ELECTRICALREQUIREMENTS.A120VACreceptacleneedstobelocatedwithin36inchesoftheConverter/Chargerto
supplypower.Electricalconsiderationshouldalsobegiventomountingnearthelocationsofthebatteriesandthe12voltDC
distributionpanel.
5. ELECTRICALCONNECTIONS.Besuretotightenallconnectionssecurely.Alooseconnectioncanquicklycauseterminals
andwirestooverheat.Reviewunitlabelsforrecommendedterminaltorquevalues.
WARNING–AvoidPossibleInjuryorDeath
120VACConnection–Firstconfirmthatthe120VACpowersourceACcircuitbreaker(s)areintheoffposition.DONOT
turnonACcircuitbreakersuntilinstallationiscomplete.
●Usingan8AWGminimumsizecopperwire,attachfromthevehicle/devicechassistotheConverter/ChargerBonding
Lug.
●UsingtheattachedpowercordontheConverter/Charger,connectfirmlytothe120VACreceptacle
12VDCWiring–Itisimportanttousethecorrectwiregauge.Useaminimumof8AWGsizecopperwire.
●Theterminalmarked+orPOSisfortheRV12VDCpositiveconnection.
●Theterminalmarked–orNEGisfortheRV12VDCnegativeconnection.
●The12VDCoutputwiringdoesnotrequireovercurrentprotectionbecausetheConverter/Chargerlimitscurrentoutput.
However,allelectricalconnectionsneedtocomplywiththeappropriateNECcode.
6. 4STAGECHARGINGOPTIONDESCRIPTION.Thissystemprovidesanautomaticchargingsysteminfoursteps.1.Afastchargeto
bringagood,drainedbatterybackuptofullvoltagerapidly("Boost").2.Astandardchargetobringthebatteryuptoafull
chargeatasaferatetoprolongthelifeofthebatteryandprovidepowertorun12Vlightingandappliancesinthe
vehicle/device("Normal").3.Atricklechargetokeepthebatteryfreshduringtimesofloadinactivity("Storage").4.Ahigher
Boostmodeiscycledthroughevery22hoursina24hourcontinuouscycletohelpwithbatterymaintenanceandimproved
charging.(“Desulfation”).Thechargerautomaticallychangesmodestoaccommodatechangesinconditions.
7. TEST.First,disconnectallloadsandbatteryontheConverter/Chargerbyremovingall12VDCconnectionsfrom+orPOS.
Second,attachamultimeterinstrumentbetweenthepositiveandnegativeterminalsoftheConverter/Charger.Thenenergize
the120VACconvertercircuit.Testforproperoutputpowerusingthemultimeter.Measuretheoutputvoltagefromthe
positiveandnegativeterminals.Thevoltageshouldread14.6+/0.2VDC.Add12VDCloadconnectionstoabout2/3ofthe
ratedcapacityoftheconverter.Recheckthevoltage,whichshouldremainapproximatelythesameasatnoload.
8. BATTERY.Withthe120VACdisconnected,reconnectthe+orPOSpositiveterminaltoaknowngoodbattery.Withthe
converter120VACenergized,measurethevoltageattheconverterandatthebattery.Thevoltageshouldbeaboutthe
sameinbothlocations.Aswithanybatteryitisimportantthatthefluidlevelbecheckedonaregularbasis.When
continuouslyconnectedtoanychargingsourceallbatterieswill“Gas”andlosesomefluid.
WARNING–AvoidPersonalInjury/ProductDamage
9. HIPOTTESTING.(Vehicle/deviceManufacturingFacilitiesOnly)DONOTHiPotDCwiringwiththeConverter/Charger
connectedtothevehicle/devicewiringinordertopreventseriousinjuryand/ordamage.
TROUBLESHOOTING
NOTE:BeforeremovingandreplacingtheConverter/charger,performthefollowingchecks:
a. DisconnecttheACpowerfromthevehicle/device.
b. DisconnectthewiringandBatteryfromtheConverterPositive+outputterminal.
c. ReconnecttheACpowertoenergizetheConverter.
d. Usingavoltmeter,measurethevoltageattheConverter–and+Outputterminals.
>TheConverterisOKifthevoltagereadingisbetween13VDCand14VDC(typically13.6VDC).
>Otherwisecheckthetablebelow:
CONDITION
POSSIBLECAUSE
No12VDCoutput
●120VACnotconnectedtocoachorthecoachACcircuitbreakerisinthe
offposition.
●Reversedbatteryfusesblown.(Batterywiringconnectionsare
reversed),
●Severeoverloadorshortedload.Removeallloadsandretestperabove
instructions.
●Converter/Chargerinternalfailure.
ConvertercyclesOn&Off
●Fanairflowisinadequateorblocked.(1”minimumfreeairspaceateach
endrequired)
●Converter/Chargerinternalfailure.
ReversedBatteryfusesblown
●Batterywiringconnectionsarereversed.
●Defectivebattery,possiblebadcells.
12VDCoutputistoolow
●AttachedloadexceedsratingoftheConverter/Charger.
●Defectivebattery,possiblebadcells.
●Converter/Chargerinternalfailure.
TWOYEARLIMITEDWARRANTY
Limited Warranty and Remedy: PowerMax. (“Supplier”) warrants products it sells against faulty workmanship
or the use of defective materials and that such products will conform to published specifications, drawings and
otherdescriptionsforaperiodoftwoyears.
This warranty is the only warranty made by Supplier and is in lieu of all other warranties, express or implied,
exceptastotitle,andcanbeamendedonlybyawritteninstrumentsignedbyanofficerofSupplier.
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,lossofuse,ordamagesofanykindbaseduponaclaimforbreachofwarranty.
GENERALDISCLAIMER
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
changewithoutnotice.
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.
LIMITATIONONTHEUSEOFPRODUCTS
Products are not designed for and should not be used in any lifesupport systems, nuclear facility applications,
aircraft control applications, or any other applications in which failure of the product, in any way, could reasonably
result in harm to life, property or the environment, without the specific prior written consent of an officer of
Supplier.
A life support system is defined as a product or system intended to support or sustain life and whose failure can
be reasonably expected to result in significant personal injury or death. Nuclear facility applications are defined
as any application involving a nuclear reactor or the handling and processing of radioactive materials in which the
failureofequipment,inanyway,couldreasonablyresultinharmtolife,propertyortheenvironment.
FieldstoneProductsPMB103•11161ESR70STE110•LakewoodRanch,FL34202
Phone:9412018041•Fax:9417616222
www.powermaxconverters.com
‘ReversedBattery’Fuses
ChassisBondingLug
12VDCOutputTerminals
AIRFLOWFAN
(onbackside)
.
.
.
.
Blowsairoutof
frontgrillvents.
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