PowerMax PM3 AC to DC Converter Charger Installation Manual
- June 12, 2024
- PowerMax
Table of Contents
PowerMax PM3 AC to DC Converter Charger
PM3 models 15, 35, 45, 55, 60, 65, 75, 100 and 120 Amp and 3 Stage Charging Option
Installation & Maintenance
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.
NOTICE: Products are not to be used nor are warranted in aerospace,
medical or life safety applications.
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.
- 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.
- THE FAN WILL NOT RUN ALL THE TIME. THE FAN RUNS ONLY WHEN NEEDED.
- Never Leave the PowerMax PM3-XX unattended when plugged in.
- All PM3 Products must be installed by a certified electrician.
WARNING – Avoid Possible Injury or Death
120 VAC Connection – First confirm that the 120 VAC power source AC circuit
breaker(s) are in the 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 receptacle12 VDC Wiring– It is importan t 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 OPTION DESCRIPTION.
This optional system provides an automatic charging system in three steps. 1. A fast charge to bring a good, drained battery back up to full voltage rapidly (“Boost”). 2. A standard charge 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 charge 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, voltages may vary. -
ADJUST FIXED VOLTAGE
DESCRIPTION: The unit is on the three stage charging mode firstly. 1. move the switch A to “Adjust Fixed Voltage”, move switch B gently to adjust voltage from 13~16.5V, and get a fixed output voltage. 2. make sure the voltage as 14.6V, move the switch A to ” Three stage charging”, then the unit back to standard “Three Stage Charging”, run 14.6V almost 0.5 hour, 13.6V almost 12 hours and then to 13.2V. The voltage value of 3 stage charging will be changed with fixed voltage changed when the unit on “Three stage charging”. -
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 14.6 +/- 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.
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 |
|---|---|
| . |
in the off position.
No 12 VDC output| .
.
| 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.
| .| Attached load exceeds rating of the Converter/Charger.
12 VDC output is too low| .| Defective battery, possible bad cells.
| .| Converter/Charger internal failure.
TWO YEAR LIMITED WARRANTY
Limited Warranty and Remedy: (“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 other
descriptions for a period of two 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. All PowerMax products must be installed by a certified
electrician.
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.
LIMITATION ON THE USE OF PRODUCTS
Products are not designed for and should not be used in any life-support
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 failure of equipment, in any way, could reasonably
result in harm to life, property or the environment.
Fieldstone Products PMB 103 • 11161 E SR 70 STE 110 • Lakewood Ranch, FL 34202
Phone: 941-201-8041 • Fax:
941-405-4930
www.powermaxconverters.com
FAQ’s
What is the PowerMax PM3 AC to DC Converter Charger?
The PowerMax PM3 is an AC to DC converter charger designed to convert AC power from a source such as a campground pedestal or household outlet into DC power for charging batteries and powering DC devices.
What is the primary purpose of the PM3 Converter Charger?
The PM3 Converter Charger is used to charge batteries in RVs, boats, and other vehicles, as well as to provide a stable source of DC power for onboard electronics and appliances.
What voltage and current outputs does the PM3 Converter Charger provide?
The voltage and current outputs can vary based on the specific model, but the PM3 typically converts AC input to various DC outputs suitable for battery charging and powering devices.
Is the PM3 Converter Charger compatible with different battery types?
Yes, many PM3 models are designed to be compatible with various battery types, including lead-acid batteries commonly used in RVs and boats.
Can I use the PM3 Converter Charger for different applications besides RVs and boats?
Yes, the PM3 can be used in various applications that require AC to DC power conversion, such as remote cabins, off-grid setups, and backup power systems.
Does the PM3 Converter Charger offer multi-stage charging?
Many PM3 models feature multi-stage charging, which helps optimize battery charging and extend battery life.
Can I leave the PM3 Converter Charger plugged in for extended periods?
Yes, the PM3 is typically designed for continuous use and can be left plugged in to provide a steady source of DC power or maintain battery charge..
What safety features does the PM3 Converter Charger include?
The PM3 often includes safety features such as overcurrent protection, overvoltage protection, and thermal protection to prevent damage to devices and batteries.
Can the PM3 Converter Charger handle different input voltage levels?
Yes, many PM3 models are designed to accept a range of input voltages, making them suitable for use with different AC power sources.
Is the PM3 Converter Charger easy to install?
The installation process can vary based on the specific model and application, but many PM3 models are designed for relatively straightforward installation.
Does the PM3 Converter Charger generate a lot of heat during operation?
The PM3 may generate some heat during operation, especially when charging batteries or powering devices, but it's typically within safe limits.
Can I use the PM3 Converter Charger with solar panels or other renewable energy sources?
Yes, the PM3 can be used in conjunction with solar panels and other renewable energy sources to convert the generated AC power into usable DC power.
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