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CTEK SMARTPASS Manual

1. CONGRATULATIONS on the purchase of your new CTEK professional battery management unit This unit is part of a range of professional battery chargers from CTEK SWEDEN AB It represents the latest technology in battery charging Using the CTEK D250S DUAL and SMARTPASS products you can maximize the performance of your 12VDC source SAFETY The unit is designed for 12V lead acid batteries Do not use the unit for any other batteries e Use safety glasses when connecting or disconnecting a battery e Battery acid is corrosive Rinse immediately with water if acid comes into contact with skin or eyes Seek medical advice e Make sure that the cables are not being pinched and are not in contact with warm surfaces or sharp edges While charging a battery can emit explosive gases avoid sparks in the immediate area Always provide for proper ventilation during charging Avoid covering the unit D250S DUAL is not reverse polarity protected Disconnect battery poles before installation All installations on boats must follow ISO 10133 Please note 1 Connections from the battery must be fused close to the battery 2 Batteries must be permanently mounted in ventilated areas 3 Cables must be placed in tubes separated from cables for 230V shore power or be attach to the surface every 300mm 4 Cables in the engine room must be rated to withstand 70 C 20015686F D250S Dual SmartPass Manual Print file 001 indd 3 D250S DUAL The D250
2. SITUATION 230 110V charger for the Service and Starter battery PROBLEM The 230 1 10V charger should charge both the Ser vice and the Starter battery and be synchronized with all other energy sources SOLUTION The single output 230 110V charger is connected directly to the Service battery The Starter battery is pulse char ged through SMARTPASS The solar panel will also charge the Starter battery through SMARTPASS TIP 6 See Tip 1 Tip 2 Tip 4 and Tip 5 The battery cables of the 230 110V charger are con nected directly to the Service battery WARNING e Max 22V input e Do not connect two solar panels in series INSTALLATION SHEET 5 STARTER BATTERY 20015686F D250S Dual SmartPass Manual Print file 001 indd 10 SERVICE BATTERY INSTALLATION SHEET 6 STARTER BATTERY SERVICE BATTERY 2011 12 20 11 19 37 CONNECTING CONSUMERS SITUATION Connection of consumers to the system PROBLEM Many batteries die prematu rely if they are discharged too much Too little power might be delivered to critical consumers like navigation radio and emergency lights SOLUTION Critical consumers are con nected directly to the battery Others such as refrigerator main light and heating are connected to the SMARTPASS When the Service battery is down to a critical level then the SMARTPASS disconnects these noncritical consumers TIP7 See
3. DEFINITIONS ALTERNATOR BATTERY Depending on the application it could also be referred to as Starter battery CONNECTIONS Trailer coupling Alternator SMARTPASS Alternator D250S DUAL LAMPS Error lamp Q Power lamp Ez Alternator O battery lamp Service g solar power ii battery lamp lamp FUNCTION D250S DUAL connected correctly ready to use D250S DUAL LAMP INDICATION DURING NORMAL OPERATION Wa A urwinasteapy crow Service battery charged by the alternator Service battery charged by the solar panel Service battery charged by both the alternator and solar panel Service battery fully charged Alternator battery maintained by the solar panel EXPLANATION High temperature detected at either unit or service battery RECOMMENDATION Consider relocationg unit and or service battery Service battery connec tion problem detected Check Service battery connection and fuse Service battery connec tion problem detected Check Service battery connection and fuse Service battery connec tion problem detected Check Service battery connection and fuse Alternator battery lamp Alternator running Service battery lamp Charging of Service battery Solar panel lamp Solar panel in operation 4 EN 20015686F D250S Dual SmartPass Manual Print file 001 indd 4 Steady
4. Max 22V input INSTALLATION SHEET 1 8 EN 20015686F D250S Dual SmartPass Manual Print file 001 indd 8 SERVICE BATTERY INSTALLATION SHEET 2 STARTER BATTERY SERVICE BATTERY 2011 12 20 11 19 35 LARGE BATTERY BANK SITUATION One alternator feeding a Starter battery and a large Service battery bank PROBLEM The Starter battery will not be fully charged and might not always be able to start the engine SOLUTION The D250S DUAL recharges the Starter battery quickly to 100 which guarantees trouble free engine starts TIP 3 Mount the temperature sensor on the Starter battery WARNING Max 22V input SOLAR PANEL SITUATION One alternator and a Solar panel feeding a Starter battery and a small Service battery PROBLEM The Service battery will take a very long time to recharge due to low alternator voltage he Solar panel is difficult o synchronize with the alterna tor Due to these issues the battery will underperform and die prematurely SOLUTION The D250S DUAL charges the Service battery quickly and very efficiently from both the Alternator and the Solar pa nel The Solar panel produces at its maximum power point when the engine is off When both the Solar panel and the Alternator are on the Solar panel adjusts to the Alternator The battery will be fully charged produce more and last significantly longer TIP 4 See
5. Print file 001 indd 7 DRILL TEMPLATE aa a EN 7 2011 12 20 11 19 34 SOLAR PANEL SITUATION Solar panel PROBLEM A solar panel with 36 cells produces maximum power at about 17V Many regulator reduce the voltage by bur ning off energy SOLUTION The D250S DUAL searches for the Maximum Power Point and charges the battery perfectly with very high efficiency TIP 1 Mount the temperature sensor on the Service battery Boat All installation should be done in accordance with 1SO10133 WARNING e Max 22V input Do not connect two solar panels in series SMALL SERVICE BATTERY SITUATION One alternator feeding a Starter battery and a small Service battery PROBLEM The Service battery will take a very long time to recharge due to low alternator voltage Due to this the battery will under perform and die prematurely SOLUTION The D250S DUAL charges the Service battery quickly and very efficiently The battery will be fully charged produce more and last significantly longer TIP 2 Refer to Tip 1 Alternators with voltage sensor cables should connect this on the Starter battery 3 Caravan trailer For 13 pole contact connect D250S DUAL alternator bat tery to pin 9 Connect pin 13 to D250S DUAL vehicle ground WARNING
6. S DUAL has 2 inputs The Service battery will be charged from the alternator solar panel or both in combination The solar panel adjusts itself to the Starter battery voltage The Starter battery will be charged and maintained directly by the solar panel if the Service battery is fully charged D250S DUAL E FEATURES e Multi step 20A temperature compensated battery charging and battery maintenance e Battery separation of Starter and Service batteries e Maximum power point tracking for solar panels charging the Service battery Two power source inputs alternator solar wind Supply battery and other Coordination of the two inputs allowing parallel operation The solar input will also charge and maintain the Starter battery Built in battery guard for the starter battery Solar panel Vehicle ground Solar panel Temperature sensor L 2m a Gik Alternator battery Service battery EN 3 2011 12 20 11 19 31 DEFINITIONS SOLAR PANEL Depending on the application it could also be referred to as PV panel Photovoltaic panel CONNECTIONS Solar panel Wind power DEFINITIONS SERVICE BATTERY Depending on the application it could also be referred to as House battery Domestic battery Consumer battery CONNECTIONS Electrical equipment Battery bank SMARTPASS service battery D250S DUAL LAMP FUNCTION Power lamp
7. Tip 1 Tip 2 Tip 4 Tip 5 and Tip 6 High current consumers gt 80A should be connected directly to the Service or Starter battery WARNING e Max 22V input Do not connect two solar panels in series STARTER BATTERY 20015686F D250S Dual SmartPass Manual Print file 001 indd 11 SERVICE BATTERY EN 11 2011 12 20 11 19 39 CHARGING PROGRAM D250S DUAL The charger starts charging the target battery when the supply voltage exceeds 13 1V for 5 sec engine on The charger stops charging the target battery when the supply voltage drops below 12 8V for 10 sec engine off DESULPHATION BULK CES cee PULSE ku Q pari O j O CURRENT A STEP 1 DESULPHATION STEP 4 FLOAT Detects sulphated batteries Pulsing current and voltage removes sulphate from the lead plates of Maintaining the battery voltage at maximum level by providing a constant voltage charge the battery restoring battery capacity STEP 5 PULSE STEP 2 BULK Maintaining the battery at 95 100 capacity The charger monitors the battery voltage and gives Charging with maximum current until approximately 80 battery capacity a pulse when necessary to keep the battery fully charged STEP 3 ABSORPTION Charging with declining current to maximize up to 100 battery capacity 12 EN 20015686F D250S Dual SmartPass Manual Print file 001 indd 12 2011 12 20 11 19 39 CABLE DIMENSIONS Recommended minimum cable
8. Tip 1 and Tip 2 WARNING e Max 22V input e Do not connect two solar panels in series INSTALLATION SHEET 3 SERVICE BATTERY 20015686F D250S Dual SmartPass Manual Print file 001 indd STARTER BATTERY INSTALLATION SHEET 4 STARTER BATTERY CREL SERVICE BATTERY EN 9 2011 12 20 11 19 36 LARGE SERVICE BATTERY SITUATION One alternator feeding a Starter battery and a large Service battery PROBLEM The Service battery will take a very long time to recharge due to low alternator voltage and restrictions in how the alternator current is used The Solar panel is difficult to synch ronize with the alternator Due to these issues the battery will underperform and die prematurely SOLUTION The SMARTPASS separates the two battery banks when the engine is off With the engine on the alternator charges the service battery with its maximum current until it has tapered off to the D250S DUAL max level Then the D250S DUAL charger finalizes the charge The recharge time is minimized Solar panels are easily integrated and synchronized if a D250S DUAL is used together with the SMARTPASS TIP 5 See Tip 1 Tip 2 and Tip 4 Wires that are connected to both SMARTPASS and D250S DUAL should be connected to SMARTPASS WARNING e Max 22V input Do not connect two solar panels in series CONNECTING AC DC CHARGERS
9. d 14 CTEK PRODUCTS ARE PROTECTED BY Patents EP10156636 2 pending US12 780968 pending EP1618643 US7541778 EP1744432 EP1483817 pending SE524203 US7005832B2 EP1716626 pending SE526631 US7638974B2 EP1903658 pending EP09180286 8 pending US12 646405 pending EP1483818 SE1483818 US7629774B2 EPO9170640 8 pending US12 564360 pending SE528232 SE525604 SUPPORT Designs RCD 509617 US D575225 US D580853 US D581356 US D571179 RCD 321216 RCD 000911839 RCD 081418 RCD 001119911 0001 RCD 00111991 1 0002 RCD 081244 RCD 321198 RCD 321197 ZL 200830120184 0 ZL 200830120183 6 RCD 001505138 0001 RCD 000835541 0001 RCD 00083554 1 0002 D596126 D596125 RCD 001705138 pending US D29 378528 pending RCD 201030618223 7 pending US RE42303 US RE42230 2011 09 19 Trade marks CTM 669987 CTM 844303 CTM 372715 CTM 3151800 CTM 1461716 pending CTM 1025831 CTM 405811 CTM 830545751 pending CTM 1475420 pending CTM 1935061 pending V28573IP00 CTM 1082141 pending CTM 2010004118 pending CTM 4 2010 500516 pending CTM 410713 CTM 2010 05152 pending CTM1042686 CTM 766840 pending CTEK offers professional custom support www ctek com For the latest revised user manual see www ctek com By e mail info ctek se by telephone 46 0 225 351 80 by fax 46 0 225 351 95 By mail CTEK SWEDEN AB Rostugnsvagen 3 SE 776 70 VIKMANS HYTTAN SWEDEN VIKMANSHYTTAN SWEDEN 201 1 09 01 AZ tra Sa Beng
10. dimensions in mm MIN CABLE DIMENSIONS UNIT CABLE 5m ond lt 2 a n e N q S wa e N N a Use included connectors if possible Consider above recommendation if the units are mounted at different locations 20015686F D250S Dual SmartPass Manual Print file 001 indd 13 TECHNICAL SPECIFICATIONS Charger model Model number Max input voltage Charging voltage Charging current Back current drain Ripple Ambient tempe rature Charger type Battery types Battery capacity Dimensions Insulation class Weight MPPT D250S DUAL SMARTPASS D250S Dual 1044 SMARTPASS 1058 22V 22V 14 4V at 25 C temperature fa compensated 20A 80A lt 1Ah month lt 1Ah month lt A 20 C to 50 C output power is reduced automatically at high temperatures 5 step fully automatic charging All types of 12V lead acid batteries WET MF Ca Ca AGM and GEL 40 300Ah 28 800Ah 192 x 110 x 65mm Lx W x H IP65 splash and dust proof 0 73kg 0 74kg Yes The quality of the charging voltage and charging current are very important High current ripple heats the battery and ages the positive electrode High voltage ripple can damage other equipment connected to batteries The battery chargers from CTEK produce very high quality voltage and current with low ripple MPPT Maximum Power Point Tracking finds the best combination of supply current and voltage to maximize th
11. e power output This is especially important for Photovoltaic Solar Panels and trailer campers with wiring constraints EN e 13 2011 12 20 11 19 39 TEMPERATURE PROTECTION SMARTPASS has a temperature sensor cable The units will automatically protect the service battery if the temperature and charging voltage together are too high Charging will then only be performed by the D250S battery charger The temperature should be measured close to the bat tery therefore attach the sensor to the battery LIMITED WARRANTY CTEK SWEDEN AB issues this limited warranty to the original purchaser of this product This limited warranty is not transferable The warranty applies to manufacturing faults and material defects for 2 years from the date of purchase The customer must return the product together with the purchase receipt This warranty is void if the battery charger has been opened handled carelessly or repai red by anyone other than CTEK SWEDEN AB or its authorised representatives One of the screw holes in the bottom of the charger is sealed Removing or damaging the seal will void the warranty CTEK SWEDEN AB makes no warranty other than this limited warranty and is not liable for any costs other than those mentioned above For example consequential damages are not covered Moreover CTEK SWEDEN AB is not obligated to any other warranty other than this warranty 14 EN 20015686F D250S Dual SmartPass Manual Print file 001 ind
12. ery Negative cable connection M8 i L 0 3m m OOA Temperature sensor L 2m ai Consumers 20015686F D250S Dual SmartPass Manual Print file 001 indd 5 DEFINITIONS ALTERNATOR BATTERY Depending on the application it could also be referred to as Starter battery CONNECTIONS Trailer coupling Solar panel Wind power Alternator D250S DUAL Alternator battery DEFINITIONS CONSUMERS Depending on the application it could also be referred to as Electrical equipment CONNECTIONS Electrical equipment DEFINITIONS SERVICE BATTERY Depending on the application it could also be referred to as House battery Domestic battery Consumer battery CONNECTIONS Electrical equipment Battery bank D250S DUAL Service battery SMARTPASS LAMPS Q Error lamp Power lamp 1 Service battery charging lamp 2 Alternator battery consumption lamp 3 Alternator battery charging lamp 4 Service battery consumption lamp The CTEK SMARTPASS is designed to work together with 1 2 CTEK D250S DUAL but can also be used alone EN e 5 2011 12 20 11 19 32 SMARTPASS LAMP FUNCTION STEADY Unit ready to use FLASHING SMARTPASS LAMP INDICATION DURING NORMAL OPERATION EXPLANATION Alternator battery consumption lamp Service battery charging lamp Engine running Charg
13. ing Service battery relay Too high current through High current from alternator to service battery Consu mer powered by alternator Reduced current from alternator to service battery Consumer powered by alternator consumption lamp Consumers powered by Service battery relay Too high current through Consumer powered by alternator Battery charged by D250S DUAL charger Alternator battery charging lamp Alternator battery maintained by Service battery relay Too high current through Pulse maintenance of starter battery Indicates that an error has occurred See the table below SMARTPASS LAMP ERROR INDICATION Steady lamp 0 EXPLANATI Service battery overheated Too high current through or tempera Service battery charge current Flashing lamp ure at internal relay Too high RECOMMENDATION Check condition and or installation Check service battery Reduce alternator size or add one more D250S DUAL in parallel Service battery bank too deeply discharged 11 gt er Too high current through or tempera ure at internal relay Too many consumers connected at the same time Consider relocation of unit Reduce power usage Too high current through or tempera rent to starter battery Too high current through or tempera consumers connected ure at internal relay Too high cur ure at internal relay Too
14. lamp N 2011 12 20 11 19 31 SMARTPASS SMARTPASS can operate as a stand alone unit but works best in combination with D250S DUAL The SMARTPASS creates a priority path for charging the Service battery to recharge it more quickly and efficiently Attached energy sources like solar wind or shore power will charge both the Service and the Starter batteries through the SMARTPASS Service batteries that are overheated due to age high ambient temperature or other battery problems will be protected from high alternator current SMARTPASS FEATURES The CTEK SMARTPASS adds additional functionality for higher output alternators larger battery banks and or high parallel loads e Separation of consumers and Service batteries during charging which improves the charging capacity significantly and lowers the consumer voltage which increases expected service life of lights and other electronics e Service battery watch which avoids harmful deep discharges that otherwise would shorten battery life The battery watch also protects navigation radio and emergency light from being out of electricity e Over temperature protection of Service battery High battery temperature could significantly reduce battery life e Maintenance charge of Starter battery which simplifies installation with fewer components e Simplified installation of AC DC chargers shore power Only one output from the AC DC charger needed Alternator battery Service batt
15. many Starter battery problems check battery Relocate unit or reduce concurrent use of consumers Battery watch activated Service ba ery too low Recharge Service battery 6 EN 20015686F D250S Dual SmartPass Manual Print ile 001 indd 6 2011 12 20 11 19 32 INSTALLATION OF UNIT 1 Attach the temperature sensor holder on a flat surface on one Service battery Position it as close as possible to a positive post Use the included drill template Wiring is simplified if the units are installed according to the drill femplate but other setups are possible Install the unit s on a surface where it can be properly fixed and where the unit is not exposed o fuels oils or splashes of dirt 4 Mount the unit with screws intended for the surface and attach it with one screw in each of the our holes in the corners of the unit See picture 1 Mount the unit with M4 or ST4 2 screws The required torque depends on the surface for mounting Fig 1 shows a CTEK D250S The same procedure is used for all devices 5 Attach the cables and mount the cable screws with a torque of 7 Nm Use tool hand power without tools is not enough 6 The ground cable of the SMARTPASS should be connected to the ground screw of the DUAL or o any convinient ground connection point v N j Figure 1 2Nm INSTALLATION OF CABLES Allen key a Figure 2 20015686F D250S Dual SmartPass Manual
16. t Hagander President CTEK SWEDEN AB 20015686F 2011 12 20 11 19 39

CTEK SMARTPASS Manual

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