Vanner VANN-Guard 71 Series User manual

VANNER Incorporated Owner’s Manual
Ruggedized Battery Equalizer OWNER’S MANUAL 1
71-Series
Battery Equalizer
Table of Contents
Introduction  3
Specifications   4
Theory of Operation  6
Installation Instructions   7

VANNER Incorporated Owners Manual
Ruggedized Battery Equalizer OWNER’S MANUAL 2
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VANNER Incorporated Introduction
Ruggedized Battery Equalizer OWNER’S MANUAL 3
Introduction
Thank you for purchasing a Vanner VANN-Guard Battery Equalizer We are confident that you will be
very pleased with its performance The 71 Series is designed and manufactured by skilled professionals
using the highest standards in workmanship With minimum maintenance and care, you can be assured
of many years of trouble free service
General Description
The Vanner VANN-Guard Battery Equalizer is an efficient and highly reliable method of obtaining a 12
volt DC power source from a 24 volt DC electrical system The equalizer makes the batteries look like
they are in series and parallel at the same time In addition to providing regulated 12 volt power, the
system ensures that battery voltages remain equal which significantly extends battery life The equalizer
is designed to save your batteries and the money you would spend replacing them Users of the Vanner
battery equalizers know that it is the most cost effective and dependable solution for dual voltage
systems
A typical system would include a 24VDC power source, such as an alternator, two 12 volt battery banks in
series, and the battery equalizer The equalizer connects to the 24 volt, 12 volt and ground terminals of
the battery system When the 12 volt loads require power, the equalizer ensures that the current is taken
equally from both batteries, and that the voltages of the two batteries are kept equal This equalization
ensures extended battery life and provides a stable 12 volt supply for operating accessories
Parallelin equalizers:
Vanner Battery Equalizers may be operated in parallel to provide more power.
NOTE: The Vanner VANN-Guard Battery Equalizer is an extremely reliable device and, when installed
according to the instructions, will provide reliable operation for an indefinite period of time However, if a
system abnormality should develop that would cause an equalizer malfunction, damage to the battery
system could result if 12 volt loads are present

VANNER Incorporated Specifications
Ruggedized Battery Equalizer OWNER’S MANUAL 4
Specifications
71-Series Equalizers
Model Number 71-60 71-80 71-100
Input Voltage 24v 18 to 32 v
Efficiency (Peak) >96% >96% >96%
Max 24v Input Amps 32 43 53
Output Voltage (Input Voltage/2) ±2%
Output Amps (12v) 0-60 0-80 0-100
Standby Current 20 milliamps nominal at 28 4V
Operating Temp -40°C to +95°C (-40°F to 203°F)
Storage Temp -54°C to +105°C (-65°F to 221°F)
Serviceable No No No
Mounting Location
Mount on a flat surface close to the batteries to allow short cable runs
Location should be protected from battery acid and gases
Weights 11 7 lbs 11 7 lbs 11 7 lbs
Electrical and Environmental Specifications
Standoff Voltage 32Vdc
Reverse Polarity 30V
Heat Sink Temp 90°C
Input Under Voltage Hysteresis 150mV each battery
Input Over Voltage Turn Off 43Vdc
Over-Temp Limit 100°C
Over Temp Hysteresis ± 5°C
Load Dump SAE J1113/11 OCT1997
ESD – Handling ±15kV SAE J1113/13 OCT1997
ESD – In Vehicle ±8kV Direct, ±15kV Air SAE J1113/13 OCT1997 Class C
EMI Immunity EN61000-4-6
EMI Emissions EN55022 Class B
Thermal Shock SAE J1455 JUN2006 Section 4 1 3 2
Thermal Cycle SAE J1455 JUN2006 Section 4 1 3 1
Humidity SAE J1455 JUN2006 Section 4 2
Chemical Splash SAE J1455 JUN2006 Section 4 4
Pressure Wash SAE J1455 JUN2006 - Section 4 5
Immersion IPX8 ANSI/IEC 60529-2004
Dust Bombardment IP6X ANSI/IEC 60529-2004
Salt Spray 96hrs SAE J1455 JUN2006 Section 4 3
Mechanical Vibration SAE J1455 JUN2006 Section 4 10
Handling Shock SAE J1455 JUN2006 Section 4 11 3 1

VANNER Incorporated Specifications
Ruggedized Battery Equalizer OWNER’S MANUAL 5
Chart 1
Chart 2
90%
91%
92%
93%
94%
95%
96%
97%
98%
0 10 20 30 40 50 60 70 80 90 100
Efficiency
Output Amps
71-100 Operating Efficiency
0
10
20
30
40
50
60
70
80
90
100
110
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
Output Amps
Ambient Temperature C°
71-100 Performance above 55°C

VANNER Incorporated Specifications
Ruggedized Battery Equalizer OWNER’S MANUAL 6
71 Series Dimensional Specifications
10 6
(269)
8 0
(203)
1 3
(33)
8 5
8 0
(203)
(216)
5 1
(130)
0 31
(7)
(91)
3 2
(81)
3 6
5/16-18 x 9/16
STUD
TORQUE 120
LB-IN MAX

VANNER Incorporated Theory of Operation
Ruggedized Battery Equalizer OWNER’S MANUAL 7
Theory of Operation
In many 24 volt electrical systems it is desirable to tap into the battery system to obtain power for 12 volt
loads This method, while seemingly simple, causes a charge imbalance resulting in Battery B (see
diagram) being overcharged, and possibly boiling, while Battery A discharges
To solve this application problem the Vanner Battery Equalizer is connected to the battery system at the
+24 volt, +12 volt, and ground points The equalizer makes the batteries look like they are in series and in
parallel at the same time The equalizer maintains the voltage balance and therefore the charge
acceptance rate of each battery The equalizer will hold Battery A and B voltages to within 0 05 volts
under light loads and to within 0 1 volts at full rated load
When the voltage of Battery A is higher than or equal to Battery B the equalizer is in the standby mode,
i e , it is not transferring power from its 24 volt input to its 12 volt output When a 12 volt load is added,
and Battery A's voltage decreases to just below the voltage of Battery B, the equalizer activates and
transfers sufficient current from Battery B to Battery A to satisfy the load and maintain an equal voltage
and charge in both batteries
A key advantage of a system containing an equalizer, compared to a DC to DC converter, is that if the 12
volt load requires a momentary surge current which exceeds the rated capacity of the equalizer, Battery A
will supply the extra current to the load The equalizer will then replenish the energy to Battery A after the
surge has passed
The following scenarios describe the equalizer operation
Scenario #1 - 24 volt load present, no 12 volt load present. The system operates as a system would
without the equalizer whether the alternator is ON or OFF The equalizer is in standby mode except for
making small adjustments to keep the batteries in balance
Scenario #2 - Both 24 volt and 12 volt loads present, alternator is OFF. The equalizer will insure that
both batteries will discharge at the same rate even if different loads are present
Scenario # 3 - Both 24 volt and 12 volt loads present, alternator is ON. The alternator provides 24
volt power to the battery system and to the 24 volt loads The equalizer transfers power from the 24 volt
source to the 12 volt load by converting 24 volt power to 12 volts It will supply sufficient 12 volt power to
satisfy the 12 volt load and to maintain battery voltage balance
+
12 V
Battery A
-
+12 Volt
Loads
+24 Volt
Loads
+
12 V
Battery B
-
+
24V
Alt
-
Equalizer
+24V
GND
+12V
F1
F2
+12V
+24V

VANNER Incorporated Installation Instructions
Ruggedized Battery Equalizer OWNER’S MANUAL 8
Installation Instructions
Do not exceed the specified torque of 120 in-lbs. when connecting cables to the terminal posts ( 24,
GND, 12) during installation of the equalizer. Torque values higher than specified may damage the
product, reduce performance, and/or create hazardous conditions. Products damaged by improper torque
are not covered by the warranty.
Do not connect more than one conductor per terminal post on the equalizer. Multiple wires and
cables may overstress internal components, resulting in poor performance or creating hazardous
conditions. Products damaged by the installation of multiple conductors per post are not covered by the
warranty.
Fault protection devices must be installed between the equalizer and the power source (batter ). A
fault protection device would be any fuse or circuit breaker properly rated for the maximum DC current
obtainable. This advisory is in accordance with SAE, NEC and UL, for mobile power applications. Install
per applicable codes or within 18” of the battery. See Wire and Fuse Sizing Chart on page 9 of this
manual or contact Vanner at 1-800-227-6937 or [e-mail] if assistance is needed in sizing
fault protection devices.
Caution: This equipment tends to produce arcs and sparks during installation To prevent fire or
explosion, compartments containing batteries or flammable materials must be properly ventilated Safety
goggles should always be worn when working near batteries
Mountin Location: The equalizer may be mounted in any orientation, on a flat mounting surface
suitable to support the equalizer during operation Do not mount in zero-clearance compartment that may
result in the equalizer overheating Locate so that contact by people is unlikely
Environmental Protection: The equalizer has been designed to withstand direct exposure to rain and
moisture The has also been tested for exposure to direct pressure spray, (IP68 rating)
Reverse Polarity Protection and Wirin Sequence: The equalizer is internally protected against
reverse polarity If the 24v, 12v and GND wires are connected to the equalizer incorrectly, the equalizer
will not be damaged and will do nothing The wiring sequence is not an issue The wiring sequence is not
an issue It does not matter which wire is connected first, second or last
Strain Relief: The equalizer has an integral strain relief that installs onto the front of the unit The
equalizer is designed with wells for the lug to sit into to resist bolt loosening from cable movement, and
the strain relief is designed to further inhibit cable movement The diagram below shows the proper
orientation for the attachment of the strain relief and the #10-32 mounting hardware that is supplied
MOUNTING SCREWS
CABLE STRAIN RELIEF
LUG WELLS
VANN-Guard

VANNER Incorporated Installation Instructions
Ruggedized Battery Equalizer OWNER’S MANUAL 9
Caution addin 12volt batteries
In certain applications it may be desirable to have additional 12 volt “House Batteries” to operate heavy
12 volt (inverter) loads Use the equalizer to charge the additional batteries
Connect the equalizer 12V terminal to the additional batteries only Do not connect the equalizer 12V
terminal to both battery banks as this would make Battery A larger than Battery B Dama e to Battery B
may occur durin char in due to overcharging, if the equalizer cannot keep up with the charging
system
Caution usin a Ground-Side Battery Disconnect Switch
The system must be wired as shown to prevent Reverse Polarity Damage to polarity sensitive12 volt
loads while the ground-side disconnect switch is open The equalizer GND terminal must be wired to the
battery side of the ground-side disconnect switch circuit for the equalizer to work properly
Install the external High Current Diode, such as Vanner Model 52-75 (45 amp continuous rating) to
protect polarity sensitive 12 volt loads if these loads do not already contain input diode protection This
prevents a reverse polarity on the 12 volt equipment when the battery switch is open The reverse polarity
does not come from the equalizer, but from any 24 volt equipment that may be turned ON
+
12 V
Battery A
-
+
12 V
Battery B
-
+
24V
Alt
-
Equalizer
+24V
GND
+12V F1
F2
+24V
+
12 V
Add'l Battery
-
+
12 V
Add'l Battery
-
+
12 V
Add'l Battery
-
+12V
+
12 V
Battery A1
-
+
12 V
Battery B
-
+
24V
Alt
-
Equalizer
+24V
GND
+12V F1
F2
+24V
+
12 V
Battery A2
-
+
12 V
Battery A3
-
+
12 V
Battery A4
-
+12V
F1
Acceptable
Battery A and Battery B Are
The Same Size
Unacceptable
Battery A and Battery B Are
NOT The Same Size
+
12 V
Battery A
-
+12 Volt
Loads
(Radio)
+24 Volt
Loads
+
12 V
Battery B
-
+
24V
Alt
-
Equalizer
+24V
GND
+12V
F1
F2
+12V
+24V
High Current Diode
Battery Disconnect Switch

VANNER Incorporated Installation Instructions
Ruggedized Battery Equalizer OWNER’S MANUAL 10
Wire Size and temperature ratin
Cables connecting the equalizer to the batteries must be sufficiently sized to prevent unwanted voltage
drops To properly maintain battery voltage balance, the voltage drop (loss) must be less than 0 05 VDC
between the equalizer +24 volt terminal and the battery +24 volt terminal (Battery B positive terminal);
less than 0 10 VDC between the equalizer +12 volt terminal and the battery +12 volt terminal (the jumper
between Battery A and Battery B); and less than 0 05 VDC between the equalizer GND terminal and the
battery ground terminal (Battery A negative terminal that is connected to chassis ground) In most
installations, the equalizer terminals are wired directly to the battery terminals (reference fault protection)
to prevent voltage loss that could occur in switch contacts, connections, and long wire runs
Wire and Fuse Size Chart
Wire Size
AWG
Max wire length, in feet, between equalizer and battery to keep voltage drop under 0 1 volt The
chart assumes the wire carries no other load and wire temperature is below 80ºC
71 Series 2 X 71 Series
#4 3 5 XXX
#2 5 2 2 6
#1 6 5 3 3
#1/0 8 3 4 1
#2/0 10 5 5 3
Fuse F1 125 amp 250 amp
Fuse F2 80 amp 150 amp
Verify Equalizer Operation
Before testing the equalizer, be sure all battery connections are good and that fuses F1 and F2 are good
Equipment Required
• VoltMeter having 0 01 volt resolution (Fluke Model 87 Multimeter recommended) (Use two
multimeters if it is desirable to see the voltages of Battery A and Battery B at the same time )
• Clamp-on amp meter (Fluke Model 36 Clamp-on Meter recommended)
The equalizer is working properly if:
1 The 12 volt DC loads are being operated continuously and are within the rated capacity of the
equalizer and;
2 Battery A voltage is lower than Battery B by no more than 0 05 to 0 10 volts, measured at the
equalizer’s +24, +12 and GND terminals