IOTA DLS Series Power Converter-Battery Charger Owner’s Manual

IOTA DLS Series Power Converter-Battery Charger

Product Information

The DLS Series 220-240VAC Power Converter/Battery Charger is an electrical device designed and manufactured by IOTA. It has protection features such as reverse battery polarity protection, brown-out input protection, over-current protection (cycle-by-cycle peak limiting as well as rated current limiting), and over-temperature protection. It also has a proportional fan control circuit that enables the fan to turn on and off slowly, minimizing unwanted fan-starting noise. The product comes with a two-year warranty from the date of retail purchase for defects in materials or workmanship.

Product Usage Instructions

1. Before installing and operating the DLS Power Converter/Battery Charger, read all instructions and safety precautions carefully.
2. Observe the guidelines provided in the user manual when working with the DLS unit to avoid electrical shock, explosion, and fire hazards.
3. Do not cut power cords, submerge the charger in water, or get it wet to prevent electrical shock.
4. Do not attempt to charge damaged or frozen batteries. Use the charger only with batteries of recommended voltage and operate it in well-ventilated areas only to prevent explosion hazards.
5. Keep the charger away from combustible materials and avoid smoking or using any other source of electrical spark or fire when operating the charger to prevent fire hazards.
6. Working in the vicinity of lead-acid batteries is dangerous because they generate explosive gases during normal battery operation. To reduce the risk of battery explosion, follow the instructions published by the battery manufacturer and review all cautions and warnings associated with these products.
7. If you encounter any issues with the DLS Power Converter/Battery Charger, contact Customer Service or visit www.iotaengineering.com for warranty details and repair or replacement options.

Thank you for purchasing IOTA’s DLS-240-27 Power Converter/Battery Charger. When utilized properly, your DLS Power Converter/Battery Charger will provide years of dependable service. This Owner’s Manual contains important safety and operating instructions. READ ALL INSTRUCTIONS AND SAFETY PRECAUTIONS CAREFULLY BEFORE INSTALLING AND OPERATING THE UNIT.

PRECAUTIONS

WARNING: Risk of SERIOUS INJURY OR DEATH

This unit is an electrical device. When working with this, or any electrical device, there exists the potential for ELECTRICAL SHOCK, EXPLOSION and FIRE hazards. Before using this equipment, READ AND UNDERSTAND the instructions, warnings, and safety precautions in this Owner’s Manual. Failure to read and understand these instructions could result in SERIOUS INJURY or DEATH.

SAVE THESE INSTRUCTIONS

CAUTION

When working with the DLS unit, always observe the following guidelines:

• The DLS is designed for indoor use. Do not use outdoors.
• DO NOT expose the DLS unit to rain, snow, or other inclement weather.
• Do not mount the DLS in a zero clearance compartment or in compartments with flammable items such as gasoline or batteries.
• Do not mount the DLS in an area with the potential of dust, debris, or other foreign materials entering the vents of the DLS.
• Use of an attachment or device with the DLS not recommended by IOTA Engineering will void the warranty and may result in a risk of fire, electrical shock, or injury to persons.
• To reduce the risk of damage to the electric plug and cord, always pull by the plug and not the cord when disconnecting the unit.
• DO NOT operate the DLS with a damaged cord or plug.
• DO NOT operate the DLS if it has been dropped, received a sharp blow, or has been otherwise damaged in any way. Take the DLS unit to a qualified service location.
• DO NOT disassemble the DLS unit. Take the DLS to a qualified service location when service or repair is required.
• To reduce the risk of electric shock, DISCONNECT the DLS charger from ALL power sources before attempting any maintenance or cleaning. Turning off any electrical supply or load to the unit is not sufficient and will not reduce this risk.
• DO NOT use extension cords. Using an improper extension cord could result in a risk of fire and electric shock, and may result in property damage, personal injury or death.

DANGER

ELECTRICAL SHOCK HAZARD

• THIS CHARGER IS AN ELECTRICAL DEVICE THAT CAN SHOCK AND CAUSE SERIOUS INJURY.
• DO NOT CUT POWER CORDS.
• DO NOT SUBMERGE IN WATER OR GET THE CHARGER WET.

EXPLOSION HAZARD

• UNSUPERVISED, INCOMPATIBLE, OR DAMAGED BATTERIES CAN EXPLODE IF USED WITH A CHARGER.
• DO NOT ATTEMPT TO CHARGE DAMAGED OR FROZEN BATTERIES.
• USE THE CHARGER ONLY WITH BATTERIES OF RECOMMENDED VOLTAGE.
• OPERATE THE CHARGER IN WELL-VENTILATED AREAS ONLY.

WARNING: FIRE HAZARD

• A CHARGER IS AN ELECTRICAL DEVICE THAT EMITS HEAT AND CAN BURN.
• DO NOT COVER THE CHARGER.
• KEEP THE CHARGER AWAY FROM COMBUSTIBLE MATERIALS.
• DO NOT SMOKE OR USE ANY OTHER SOURCE OF ELECTRICAL SPARK OR FIRE WHEN OPERATING THE CHARGER.

RISK OF EXPLOSIVE GASES

• WORKING IN THE VICINITY OF LEAD-ACID BATTERIES IS DANGEROUS.
• BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION.
• FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS WHEN USING THE BATTERY CHARGER.
• To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and review all Cautions and Warnings associated with these products.

PRODUCT DESCRIPTION

IOTA DLS-240-27 Power Converter/Battery Charger convert 200-240 volts nominal A.C. to 27.2 volts D.C. As a power supply, its tightly controlled regulation allows the user to operate a D.C. load up to the converter’s rated output current. As a battery charger, the converter will maintain the battery, delivering its full-rated current when the battery capacity falls sufficiently low. The voltage is set to deliver its maximum current for the necessary period of time that minimizes undue stress to the battery caused by heating of its cells. This helps to ensure the longest possible life of the battery. Over time, as the battery nears its full capacity, the converter will float-charge the battery to prevent self-discharge of its cells.

PROTECTION FEATURES

The IOTA Power Converters/Battery Chargers are designed with high quality components to help ensure years of continuous use. The unit is protected by multiple protection features for a long, trouble-free life.

1. Reverse Battery Polarity Protection.
2. Brown-Out Input Protection.
3. Over-Current Protection – cycle by cycle peak limiting as well as rated current limiting to maximize the life of the converter.
4. Over-Temperature Protection. In addition, it is designed with a unique “proportional” fan control circuit. Fan speed is directly proportional to the converter’s internal ambient temperature. This enables the fan to turn on and off very slowly, minimizing unwanted fan-starting noise.

WARRANTY

The IOTA Power Converters/Battery Chargers are warranted from defects in materials or workmanship for two years from date of retail purchase, and limits the remedies to repair or replacement. This warranty is valid only in the continental United States and Canada. For complete warranty details, contact Customer Service or visit www.iotaengineering.com.

INSTALLATION GUIDELINES

MOUNTING LOCATION

• The IOTA Power Converter/Battery Charger can be mounted in any position within an enclosed or interior compartment. Provide sufficient air space to allow unrestricted airflow in and around the unit. Provide at least 4″ around the fan of the DLS to allow for proper air intake.
• DO NOT mount the unit in a zero clearance compartment.
• DO NOT mount the DLS in the same compartment with flammable items such as gasoline or batteries. There are no components within the DLS unit that, during normal operation, produce arcs or sparks. However, all electronic devices have some potential for generating sparks in the event of failure which can result in explosion or fire.
• DO NOT mount the DLS in an area that has the potential of dust, debris, or other foreign materials to enter in through the DLS vents.
• DO NOT place the DLS directly above the battery; the gases from the battery can corrode and damage the DLS.

240 VOLT A.C. INPUT

Plug the unit A.C. input cord into an appropriate 220-240 volt 3-wire grounded source. Refer to Illustration 2 for the specifications of the cord provided with your DLS unit. See the Technical Specifications Chart on page 4 for maximum current draw and required input voltages.

• DO NOT USE EXTENSION CORDS – Using an improper extension cord could result in a risk of fire and electric shock, and may result in property damage, personal injury or death.
• DO NOT OPERATE THE DLS WITH A DAMAGED CORD OR PLUG. Have the cord or plug replaced immediately by qualified service personnel.
• To minimize the possibility of arcing at the battery, connect the IOTA power cord to the AC input BEFORE connecting the battery.

_ Note: _occasionally a small spark or arc may occur at the power outlet as the unit is plugged in. This is a common occurrence due to the internal capacitors drawing power.

BATTERY CONNECTION

Disconnect the positive side of the battery before installation. Connect the positive (red) and negative (black) terminal lugs to battery or load. Always use the proper size wire based on the amperage of the converter and the battery. Recommended wire gauge and torque are as follows: 4-6 AWG at 45 in. -lbs, 8 AWG at 40 in. -lbs. Refer to Illustration 1. Recreational vehicle applications require a type III circuit breaker be installed within 18″ of the battery, connecting the battery positive to the line side of the breaker, and the IOTA unit to the load side. Connect “Chassis Bonding Lug” on the IOTA unit to vehicle chassis or other grounding source. Refer to Illustration 1.

REVERSE POLARITY FUSES

The IOTA Battery Charger/Power Supply is protected against reverse polarity on the DC output. If a battery or the unit is hooked up incorrectly, the fuses will blow and can be easily replaced. Always use the same size and style fuse that came with the converter. To change the fuses, use a screwdriver to loosen the screws and remove the fuses. Always replace the fuses with the same type and rating.After inserting the new fuses, tighten the screws firmly. Apply 5 inch-pound maximum torque. DO NOT OVERTIGHTEN. Note: some DLS models require only one fuse. For these units, a small fiberglass spacer may be used in the empty fuse slot to aid with tightening.

CHARGE CONTROL

TWO-STEP VOLTAGE JACK

The two-step voltage jack allows switching from a long-term float voltage to a ‘high-stage’ voltage. When the included dual voltage plug is inserted in the jack*, the voltage rises to a bulk voltage for occasional fast charging. When the plug is removed, the voltage drops to the float voltage to reduce battery water loss (voltages vary depending on the output ratings of the DLS). WARNING: To avoid battery damage, remove the Dual Voltage Plug when quick charging is complete. NOTE: If the unit is equipped with an internal IQ4 smart charger, two-step charging is not needed and the Dual Voltage Jack is disabled.

THE IQ4 LED INDICATOR

(ONLY ON IOT MODELS WITH INTERNAL IQ4)

IOTA Models with an internal IQ4 smart charger give the user the benefit of automatic Bulk, Absorption, and Float stage charging. This increases the charging capacity of the IOTA charger, decreases

charge times and insures proper and safe battery charging without over- charging. The LED on the fan end of the unit will indicate which charging phase the IOTA unit is currently in. When the unit is first activated, the LED will flash as it reads the number of cells in the battery. The unit will then proceed directly to the Bulk charging or Float charging phase depending on the charge status of the battery. Current DLS models utilize a three-color LED while earlier models feature a single-color green LED. Reference the appropriate LED CODE TABLES below for the LED codes pertaining to your particular unit. Units that do not have an internal IQ4 smart charger can easily install an external IQ4 that plugs into the available Dual Voltage Jack. Contact Customer Service for more information.

• Three-color LED Flashing code sequence intervals are 0.5 SEC on / 0.5 SEC off.

TECHNICAL SPECIFICATIONS CHART

RATINGS AND SPECIFICATIONS/ DLS-240-27-25/ DLS-240-27-40

• The unit is not UL Listed
• Primary to Chassis/Primary to Secondary/Secondary to Chassis

IOTA ENGINEERING

• PO BOX 11846 TUCSON, AZ 85734
• TEL: 1-800-866-IOTA (4682)
• FAX: 520-741-2837
• WEB: www.iotaengineering.com

68357-227 REV 2110

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