Waeco PerfectCharge MCA1215 User manual

PerfectCharge
MCA1215, MCA1225, MCA1235
EN 2 Battery charger
Installation and Operating Manual

EN
Explanation of symbols MCA1215, MCA1225, MCA1235
2
Please read this instruction manual carefully before installation and
first use, and store it in a safe place. If you pass on the product to
another person, hand over this instruction manual along with it.
Table of contents
1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Installing the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Connecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 Using the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 Maintaining and cleaning the device . . . . . . . . . . . . . . . . . . . . . . . . 27
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
13 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1 Explanation of symbols
D
!
DANGER!
Safety instruction: Failure to observe this instruction will cause
fatal or serious injury.
WARNING!
Safety instruction: Failure to observe this instruction can cause
fatal or serious injury.

EN
MCA1215, MCA1225, MCA1235 General safety instructions
3
!
A
I
2 General safety instructions
The manufacturer accepts no liability for damage in the following cases:
Faulty assembly or connection
Damage to the product resulting from mechanical influences and excess
voltage
Alterations to the product without express permission from the manu-
facturer
Use for purposes other than those described in the operating manual
Observe the following instructions:
Connection to supply mains is to be in accordance with National wiring
rules.
Before charging, read the instructions.
For indoor use. Do not expose to rain.
!
CAUTION!
Safety instruction: Failure to observe this instruction can lead to
injury.
NOTICE!
Failure to observe this instruction can cause material damage and
impair the function of the product.
NOTE
Supplementary information for operating the product.
WARNING!
Note the following basic safety information when using electrical
devices to protect against:
Electric shock
Fire hazards
Injury

EN
General safety instructions MCA1215, MCA1225, MCA1235
4
2.1 General safety
DDANGER!
In the event of fire, use a fire extinguisher which is suitable for
electrical devices.
!WARNING!
Only use the device as intended.
Disconnect the device from the mains:
– Before cleaning and maintenance
– After use
– Before changing a fuse
If you disassemble the device:
– Detach all connections
– Make sure that no voltage is present at any of the inputs and
outputs
The device may not be used if the device itself or the connection
cable are visibly damaged.
If this power cable for this device is damaged, it must be
replaced by the manufacturer, customer service or a similarly
qualified person in order to prevent safety hazards.
This device may only be repaired by qualified personnel.
Inadequate repairs may cause serious hazards.
This device can be used by children aged 8 years or over, as
well as by persons with diminished physical, sensory or mental
capacities or a lack of experience and/or knowledge, providing
they are supervised or have been taught how to use the device
safely and are aware of the resulting risks.
Electrical devices are not toys.
Always keep and use the appliance out of the reach of children.
Children must be supervised to ensure that they do not play with
the device.
ANOTICE!
Before start-up, check that the voltage specification on the type
plate is the same as that of the power supply.
Ensure that other objects cannot cause a short circuit at the
contacts of the device.
Never pull the plug out of the socket by the connection cable.
Store the device in a dry and cool place.

EN
MCA1215, MCA1225, MCA1235 General safety instructions
5
2.2 Safety when installing the device
DDANGER!
Never mount the device anywhere where there is a risk of gas
or dust explosion.
!CAUTION!
Ensure that the device is standing firmly.
The device must be set up and fastened in such a way that it
cannot tip over or fall down.
ANOTICE!
Do not expose the device to a heat source (such as direct
sunlight or heating). Avoid additional heating of the device in
this way.
Set up the device in a dry location where it is protected against
splashing water.
2.3 Safety when connecting the device electronically
DDANGER! Danger of electrocution
For installation on boats:
If electrical devices are incorrectly installed on boats, corrosion
damage might occur. Have the device installed by a specialist
(marine) electrician according to AS 3000, AS 3001.
If you are working on electrical systems, ensure that there is
somebody close at hand who can help you in emergencies.
!WARNING!
Always use sockets which are grounded and secured by
residual current circuit breakers.
Make sure that the lead has a sufficient cross-section.
Lay the cables so that they cannot be damaged by the doors or
the bonnet.
Crushed cables can lead to serious injury.
!CAUTION!
Lay the cables so that they cannot be tripped over or damaged.

EN
General safety instructions MCA1215, MCA1225, MCA1235
6
ANOTICE!
Use ductwork or cable ducts if it is necessary to lay cables
through metal panels or other panels with sharp edges.
Do not lay the 230 V mains cable and the 12 V DC cable in the
same duct.
Do not lay the cable so that it is loose or heavily kinked.
Fasten the cables securely.
Do not pull on the cables.
2.4 Operating the device safely
DDANGER! Danger of electrocution
Do not touch exposed cables with your bare hands. This applies
especially when operating the device from the AC mains.
To be able to disconnect the device quickly from the mains, the
socket must be close to the device and be easily accessible.
!WARNING!
Only use the device in closed, well-ventilated rooms.
Do not operate the device in systems with lead acid batteries.
These batteries give off explosive hydrogen gas that can be
ignited by sparks on electrical connections.
!CAUTION!
Do not operate the device
– In salty, wet or damp environments
– In the vicinity of corrosive fumes
– In the vicinity of combustible materials
– In areas where there is a danger of explosions.
Before starting the device, ensure that the power supply line
and the plug are dry.
Always disconnect the power supply when working on the
device.
Please observe that parts of the device may still conduct voltage
even if the fuse has blown.
Do not disconnect any cables when the device is still in use.

EN
MCA1215, MCA1225, MCA1235 General safety instructions
7
ANOTICE!
Make sure the air inlets and outlets of the device are not
covered.
Ensure good ventilation.
2.5 Safety precautions when handling batteries
!WARNING!
Batteries contain aggressive and caustic acids. Avoid battery
fluid coming into contact with your body. If your skin does come
into contact with battery fluid, wash the part of your body in
question thoroughly with water.
If you sustain any injuries from acids, contact a doctor
immediately.
!CAUTION!
When working on the batteries, do not wear any metal objects
such as watches or rings.
Lead acid batteries can cause short circuits which can cause
serious injuries.
Danger of explosions!
Never attempt to charge a frozen or defective battery.
Place the battery in a frost-free area and wait until the battery
has acclimatised to the ambient temperature. Then start the
charging process.
Wear goggles and protective clothing when you work on
batteries. Do not touch your eyes when you are working on the
battery.
Do not smoke and ensure that no sparks can arise in the vicinity
of the engine or battery.
ANOTICE!
Only use rechargeable batteries.
Prevent any metal parts from falling on the battery. This can
cause sparks or short-circuit the battery and other electrical
parts.
Make sure the polarity is correct when connecting the battery.
Follow the instructions of the battery manufacturer and those of
the manufacturer of the system or vehicle in which the battery is
used.

EN
Intended use MCA1215, MCA1225, MCA1235
8
If you need to remove the battery, first disconnect the earth
connection. Disconnect all connections and all consumers from
the battery before removing it.
3 Intended use
The WAECO PerfectCharge MCA1215, MCA1225, MCA1235 battery
charger can charge or supply a retention voltage to batteries which are used
to generate power in vehicles or on boats.
The MCA charger can be used to continuously charge supply or starter
batteries. This allows the batteries to be charged and to maintain a high
charge level:
12 V batteries: MCA1215, MCA1225, MCA1235
The MCA battery charger are designed to charge the following battery types:
Lead starter batteries
Lead gel batteries
Absorbed glass mat (AGM) batteries
Dometic eStore Lithium-ion batteries
Never use the devices to charge other battery types (such as NiCd or NiMH).
!WARNING! Danger of explosions
Do not charge batteries with a cell short circuit. The oxy-
hydrogen they produce can cause explosions.
Do not charge lead batteries in unventilated rooms. The oxy-
hydrogen they produce can cause explosions.
Do not charge nickel cadmium and non-rechargeable batteries
with the charger. The cases of these batteries can burst
explosively.

EN
MCA1215, MCA1225, MCA1235 Scope of delivery
9
4 Scope of delivery
Check before starting up the device that all parts are available belonging to
the scope of delivery.
5 Accessories
Available as accessory (not included in scope of delivery):
Quantity Description
1 Battery charger
2 230 V power cable
3 Installation and operating manual
Description Item no.
Remote Control MCA-RC1 9102500037
Temperature sensor MCA-TS1 9102500036
Battery sensor MCA-HS1 (IBS) – Hella Sensor 9102500038
Battery Management System PerfectControl MPC01 9102500073

EN
Technical description MCA1215, MCA1225, MCA1235
10
6 Technical description
The low weight and compact construction of the battery charger allow for
easy installation in mobile homes, commercial vehicles or motor and sailing
yachts. It charges batteries that are used on board vehicles or boats to
generate power or supplies them with a retention voltage so that they do not
discharge.
A control lamp on the device enables constant monitoring in the battery
charger.
The device has the following protective systems:
Short circuit
Overheating protection
with sensor (accessory): Battery overheating
The device can also be integrated into a LIN bus using two connections.
The cooling system uses fans whose speed depends on the charging power
and can be switched off using an external switch.
6.1 Device versions
The PerfectCharge MCA battery chargers are available in different versions.
Your MCA battery charger can be used to charge batteries up to a specified
battery capacity (see chapter “Technical data” on page 29):
MCA1215: suitable for charging one supply battery and one starter
battery
MCA1225, MCA1235: suitable for charging up to two supply batteries and
one starter battery
For the identification of your device, see the item number on the type plate.

EN
MCA1215, MCA1225, MCA1235 Technical description
11
6.2 Connections and controls
12345
AC INPUT
DC OUTPUT
1234 STATUS TEMP/LIN1 LIN2
ESB
12345
AC INPUT
DC OUTPUT
123 STATUS TEMP/LIN1 LIN2
ESB
MCA1215
MCA1225/1235
1
234
987
56
1
23456
987
1

EN
Technical description MCA1215, MCA1225, MCA1235
12
No. in
fig. 1, page 11 Explanation/function
1 Mains connection
2 LIN2 bus connection
3 TENMP/LIN1 bus connection
4 CN2 socket for Alarm and Fan
5 Status LED
6 DIP switch
7 Battery terminals (+)
8 Battery terminals (–)
9 Starter battery connection
No. in
fig. 2, page 12 Explanation/function
1 On/Off switch
2Fan
MCA1215/1225/1235
21
2

EN
MCA1215, MCA1225, MCA1235 Technical description
13
6.3 Battery charging function
The charging characteristics are referred to as modified IU0U characteristics.
1: I phase (bulk)
At the beginning of the charging process, the flat battery is charged with a
constant current (100% charge current) until the battery voltage reaches the
charging voltage. The charging current decreases when the battery has
reached this charging level.
2, 3, 4: U0 phase (absorption)
Now the three-stage absorption charging process (U0 phase) begins, where
the duration depends on the battery. The voltage remains constant (U0). In
the first 2 minutes, the charging of the battery is determined. Then the main
charging phase begins when the battery is fully charged.
Once the battery is completely charged, or the charging current is below 6 %
of the rated charging current for 15 minutes, the U0 phase has finished.
U0 U
U
I
I
1
100 %
6 %
234 65
t
U/V
I/A
3

EN
Installing the device MCA1215, MCA1225, MCA1235
14
5: U phase (float)
After the U0 phase, the battery charger switches to conservation charging
function (U phase).
If DC loads are connected, they are powered by the device. Only if the power
required exceeds the capacity of the device is this surplus power provided by
the battery. The battery is then discharged until the device re-enters the I
phase and charges the battery.
6: 12-day conditioning
Every 12 days, the battery charger switches back to phase 1 for 85 min in
order to revive the battery. This prevents any fatigue symptoms such as
sulphation.
7 Installing the device
When selecting the installation location, observe the following instructions:
The device can be installed horizontally or vertically.
Do not install the device
– In wet or damp environments
– In dusty environments
– In the vicinity of combustible materials
– In areas where there is a danger of explosions.
Connection to supply mains is to be in accordance with National wiring
rules.
Before charging, read the instructions.
For indoor use. Do not expose to rain.
The place of installation must be well ventilated. A ventilation system must
be available for installations in small, enclosed spaces. The clearance
around the device must be at least 25 cm.
The air inlet on the underside and the air outlet on the back of the device
must remain clear.
For ambient temperatures higher than 40 °C (such as in engine or heating
compartments, or direct sunlight), the heat from the device under load can
lead to reduced output.
The device must be installed on a level and sufficiently sturdy surface.
Do not install the device in the same area as the batteries.

EN
MCA1215, MCA1225, MCA1235 Installing the device
15
Do not install the device above batteries, because they can emit corrosive
sulphur fumes that will damage the device.
A
For installation and mounting you will need the following tools:
Pen for marking
Drill bit set
Drill
Screwdriver
To secure the device in place you will need:
Machine bolts (M4) with washers and self-locking nuts or
self-tapping screws or wood screws.
Fasten the device as follows:
➤Hold the device against the installation location.
➤Mark the fastening points.
➤Fasten the device with one screw through each hole in the holders.
NOTICE!
Before drilling any holes, make sure that no electrical cables or
other parts of the vehicle can be damaged by drilling, sawing and
filing.

EN
Connecting the device MCA1215, MCA1225, MCA1235
16
8 Connecting the device
8.1 Connecting to battery and power supply
Connecting the battery
Observe the following instructions when connecting the battery:
!
Make sure the battery terminals are clean when connecting them.
Make sure the plug connector is fitted securely.
Select a connection cable with a sufficient cross-section (see chapter
“Technical data” on page 29).
Lay the cables in accordance with AS 3000, AS 3001.
Connect the negative cable directly to the negative terminal of the battery,
and not to the chassis of a vehicle or boat.
Use the following cable colours:
– Red: positive connection
– Black: negative connection
Do not reverse the polarity. Reversing the polarity can cause damage to
the device.
➤Lay the positive cable from the battery charger to the positive terminal of
the battery and connect it.
➤Lay the negative cable from the battery charger to the negative terminal
of the battery and connect it.
Connecting the 230 V power supply
➤Plug the 230 V connection cable included in the delivery into the MCA
battery charger‘s “AC INPUT” socket.
➤Connect the device with the he 230 V connection cable to a 230 V socket
which is protected by a residual current circuit breaker.
CAUTION!
Avoid coming into contact with the battery fluid.
Batteries with a cell short circuit may not be charged, as explo-
sive gases may form due to overheating of the battery.

EN
MCA1215, MCA1225, MCA1235 Connecting the device
17
8.2 Charge versions
– without; ✓with
fig. 4, page 17 fig. 5, page 17
Battery sensor
MCA-HS1 (IBS)
Perfect Control
MPC01
Remote control
MCA-RC1
Temperature sensor
MCA-TS1 or
Battery sensor
MCA-HS1 (IBS)
–– ––
✓–✓–
✓✓ –✓
✓✓
MPC01 MCA-HS1 (IBS)
LIN
4
MCA-RC1 MCA-TS1/MCA-HS1 (IBS)
LIN
5

EN
Connecting the device MCA1215, MCA1225, MCA1235
18
Charging the battery
➤Connect the battery to the “DC OUTPUT” socket of the MCA battery
charger.
Make sure the polarity of the connections is correct.
Charging the starter battery
➤Connect the starter battery to the “ESB” socket of the MCA battery
charger.
Make sure the polarity of the connections is correct.
Charging using the temperature sensor MCA-TS1 (accessory)
➤Connect the temperature sensor to the TEMP/LIN connection.
✓The charging voltage is adjusted according to the temperature measured.
Charging using the IBS battery sensor MCA-HS1 (accessory)
➤Connect the battery sensor to the TEMP/LIN connection.
✓The battery sensor transmits the battery temperature and the battery
voltage to the charger via the LIN communication port. The charging
voltage is regulated according to the temperature. Any potential loss of
voltage in the connecting cables is also compensated.
Charging using the battery management system PerfectControl
MPC01 (accessory)
➤Set the DIP switches 1 to 3 on the MCA battery charger to “ON” (chapter
“Setting the DIP switches” on page 23).
You can find detailed information in the operating manual for MPC01.

EN
MCA1215, MCA1225, MCA1235 Connecting the device
19
Charging using the remote control MCA-RC1 (accessory)
I
➤Insert one end of the RJ-11 cable into the socket (fig. 63, page 19) of
the MCA-RC1.
➤Insert the other end of the RJ-11 cable into the TEMP/LIN1 socket on the
MCA battery charger.
NOTE
The length of the RJ-11 cable may not exceed 7 m.
Sleep
Mode
On / Off
MCA-RC1
1
23
MCA-RC1
6

EN
Connecting the device MCA1215, MCA1225, MCA1235
20
8.3 Wiring diagrams
Example of a wiring diagram, 12 V: see fig. 7, page 20.
No. in
fig. 7, page 20 Explanation/function
1 MCA charger
2 Consumer
3 PerfectControl MPC01
4 12 V battery sensor IBS
5 12 V battery
6Fuse
7 Starter battery
2
376 4
1
5
MCA12xx
LIN
7