PowerMax AC to DC Converter/Charger User Guide
- June 3, 2024
- PowerMax
Table of Contents
PowerMax AC to DC Converter/Charger
Dual AC Input: 100-135VAC/190-240VAC
Dual Battery Type: AGM & Lithium battery
Installation & Maintenance
SAFETY ALERT: FOR YOUR SAFETY, READ ALL INSTRUCTIONS BEFORE INSTALLATION AND OPERATION.
WARNING
- Avoid Possible Injury or Death This Converter/Charger is designed to convert 120 VACI220VAC 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 “Gurrent limiting byy desialn
- Avoid Personal Injury or Product Damage.
- 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/220 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.
- 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/220 VAC Connection: First confirm that the 120 VAC/220 VAC power source AC circuit is off position. DO NOT turn-on 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/220 VAC receptacle.
12 VDC Wiring: It is important 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 MODE
Factory Setting（Lead-acid battery, AGM battery and Green LED Indicator)
This mode provides an automatic charging system in three steps. 1. A fast charge (Boost 14.6V) to bring a good, drained battery back up to full voltage rapidly. 2. A standard charge (Absorption 13.6V) 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 3. A trickle charge (Float 13.2V) to keep the battery fresh during times of load inactivity The charger automatically changes modes to accommodate changes in conditions. The chart below is for reference only, voltages may vary.
2 STAGE CHARGING MODE
（Lithium battery: LiFePO4 battery and Blue LED indicator)
This option provides an automatic charging system in two steps. 1. A fast charge (Boost 14.6V) to bring a good, drained battery back up to full voltage rapidly. 2. A trickle charge (Float 13.6V) to keep the battery both fresh during times of load inactivity to safely prolong the life of the battery and provide power to run 12V lighting and appliances in the vehicle/device. The charger automatically changes modes to accommodate changes in conditions. The chart below is for reference only, voltages may vary.
FIXED VOLTAGE MODE (Yellow LED Indicator)
The option provides a single fixed voltage that can be set between 13V to 16.5V, this provides power to run 12V lighting and appliances in the vehicle/device with or without a battery in-line. To set the unit to FIXED VOLTAGE before powering on the unit move the rear switch left (see diagram above) to “Fixed Voltage”, then power up the unit. To change the output voltage gently turn up or down the adjuster on the side of the unit to required voltage. NOTE: The output voltage you set is now fixed constantly at this level every time the unit is powered ON. To return the unit to its Factory Settings, power down the unit then move rear switch, right to “Three Stage”. Power up the unit and with a voltage meter attached to the output terminals, use side switch to gently turn the voltage up or down until you reach 14.6V. The unit is now back to the standard 3 Stage Charge mode, the Factory Setting.
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/220V AC 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/220V AC disconnected, reconnect the + or pos terminal to a known good battery. With the converter 120 VAC/220V AC 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.
TROUBLESHOOTING
NOTE: Before removing and replacing the Converter/charger, perform the following checks:
- Disconnect the AC power from the vehicle/device.
- Disconnect the wiring and Battery from the Converter Positive + output terminal.
- Re-connect the AC power to energize the Converter – or + output terminal.
- 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 |
|---|---|
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.
| | Fan air flow is inadequate or blocked. (1” minimum free air space at
each end required)
Converter cycles On & Off| |
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: Fieldstone Products, inc (“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 the 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 the Supplier under this warranty is limited solely to replacing, repairing or, at Supplier’s discretion, issuing credit for any devices which are returned by the 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
- Address: 11161 E SR 70 STE 110 Lakewood Ranch, FL 34202
- Phone: 941-201-8041
- Fax: 941-405-4930
- www.powermaxconverters.com