RanOx
Contents
1. Multi stage Smart Char ger Wu RanOx com m t Ran0x Battery Booster orton ee 4 Eo RanOx BATTERY BOOSTER USER MANUAL CONTENTS 1 1 4 1 2 1 3 1 4 2 1 3 1 3 2 4 1 4 2 4 3 4 4 4 5 6 1 6 2 6 2 1 6 2 2 6 2 3 6 3 6 4 6 5 7 1 7 2 7 3 7 4 10 11 12 12 1 12 2 12 3 13 14 15 BATTERY BOOSTER BASIC DESCRIPTION USE BRIEF FUNCTIONAL DESCRIPTION SIMPLIFIED INSTALLATION SIMPLIFIED OPERATION PRECAUTIONS RanOx BATTERY BOOSTER FEATURES and DESCRIPTION FULL FEATURE TABLE INSTALLATION RECOMMENDED WIRING and CONFIGURATIONS START UP SEQUENCE EXPLANATION of OPERATION CHARGING STAGES OUTPUT VOLTAGE CONTROL and INDICATION ADDITIONAL LCD CHARGING PHASE LEGEND FAULT INDICATIONS MAJOR FAULT INDICATIONS SET PARAMETERS and OPTION CHOICE ADDITIONAL OPERATIONS and DISPLAYS AUTOMATIC ENGINE RUNNING DETECTION TIMED TRANSFER FACILITY Description Connection Operation MASTER LOAD OFF FACILITY LOW BATTERY PROTECTION OTHER DISPLAY MESSAGES PHYSICAL OPTIONS TEMPERATURE COMPENSATION PROBE ENGINE RUN RELAY external BATTER2. RanOx Manual Rev 4H1m doc Page 13 July 2009 RanOx BATTERY BOOSTER USER MANUAL 9 SPECIFICATIONS additional information ONLY The RanOx booster is a very sophisticated device but simple to operate We have tried to provide many features in a compact affordable package The following table summarises some of the technical specifications of the product for those Users who are interested We reserve the right to vary these figures It is NOT required knowledge for satisfactory installation and operation Many items are also specified throughout the text ltem 9 Vaue Comment Input Voltage minimum 9 Volt Any input below this implies the vehicle feed is OFF Input Voltage reduce 10 Volt If input falls below this level the boost is reduced to lower the current drawn from the vehicle and hopefully raise the voltage Input Voltage maximum 16 Volt Any input above this implies faulty vehicle feed so RanOx will shutdown Output Battery Voltage min 8 Volt Below this implies faulty dead auxiliary battery Output Battery Voltage low 10 8 Volt Below this implies flat auxiliary battery RanOx will release external relay to isolate loads Above this implies auxiliary battery is normal RanOx will operate external relay to feed loads Any level above this implies faulty auxiliary battery charging maximum system so RanOx will shutdown If predicted engine alternator above threshold this implies
3. START UP SEQUENCE section Output fuse blown check replace Faulty dead caravan battery check charge replace 16 Volt charger check disconnect RanOx is supposed to be Off It is possible although unlikely for more than one fault to occur which will combine to produce other fault numbers RanOx Manual Rev 4H1m doc Page 9 July 2009 RanOx BATTERY BOOSTER USER MANUAL 5 SET PARAMETERS and OPTION CHOICE This provides the user with the ability to customise the charging parameters to suit any battery Factory defaults are provided Care should be taken with the setting of these parameters to suit the battery being charged If necessary contact your supplier for battery specifications Note that whilst setting parameters charging is disabled If you do not complete the sequence the unit will revert to normal operation after a wait Pressing and holding briefly the Set switch will briefly display SET PARAMETERS which provides the User with the ability to customise the unit to suit their application The LCD then displays Set Option x Use More Less to change or Set to step to the next function Option O This option is used when a relay controlled by the vehicle ignition circuit controls the booster supply feed No charge time out Option 1 Auto engine running detect Booster automatically detects engine status removing the requirement for a relay as in option 0 No charge time out
4. This is the Factory default option Option 2 Auto engine status detect but with a charge time limit of two hours Option 3 Auto engine status detect but with a charge time limit of three hours Option 4 Auto engine status detect but with a charge time limit of four hours Option 5 opecial Transfer facility with time limit of approximately 45 minute This does NOT change the real option but is used to manually start a timed Transfer of charge from a vehicle auxiliary battery through the RanOx to the caravan battery See below for details Note the restrictions detailed in the Installation section for these options Briefly pressing the Set switch again will display Set Float Volts on the top line and was on the lower line with the previously set voltage Use the More Less switches to change the desired float voltage Range 13 0 to 14 5 in 0 1 Volt steps Factory default is 13 5 Volt Set Float 13 6V was 13 5V Briefly pressing the Set switch again will display Set Boost and was similar to above Use the More Less switches to select desired boost also known as absorption stage of charging voltage Range 14 0 to 15 5 in 0 1 Volt steps Factory default is 14 5 Volt Briefly pressing the Set switch again will display Set Max Current and was as explained previously Use the More Less switches to select required maximum charge current For a normal lead acid battery this should be approximately 25 of the bat
5. 1 2 3 4 This diagram is for information purposes only and is subject to OPTIONAL FRIDGE RELAY change at any time RanOx Pty Ltd is NOT responsible for any damages direct indirect FRIDGE FUSE ABSORPTIQN T 30 FRIDGE arising from or related to the use of this information sheet 20A The Booster should be securely mounted close to auxiliary battery but protected from water dust and vibration The LCD display and switches should be visible accessjot Adequate ventilation MUST be provided around and under the RanOx FRIDGE ETC FEED FUSE OPTIONAL LOAD C 0 30A LOADFUSE1 RANOX INPUT r LOADFUSE2 J ad 0 2 LOAD FUSE 3 O I 2 S Sia 86 gt INPUT RanOx E E 0 z BOOSTER 5 oO gt OPTIONAL BATTERY LOAD RELAY z gt UNIT E OPTIONAL lt 4 lt Black NH 73 um 5 gative With option 1 4 selected RanOx automatically detects engine running alternator active There must NOT be any other loads sharing the RanOx feed in this configuration Suitably rated fuse s or circuit breaker s MUST protect vehicle feeds The booster feed wire should be al least 6 square mm size Any join should be soldered In line 40 Amp fuses provided protect the RanOx input and output The booster may be DESTROYED by reverse polarity connection of input or output If an absorption fridge circuit is connected directly to the battery under charge this will waste over half the maximum 25 Amp R
6. Also known as bulk stage of charging Boost Yellow Holds battery at boost voltage until almost fully charged OA when the charging current reduces significantly Also known as absorption stage of charging Optional time limits of 2 4 hour apply oe Time limit on boost has expired Holds battery at float Float Gus Hal to finalise charging ee current has reduced normally Lu uM Red blink Right hand LED indicates that caravan battery is very flat so RanOx will try to disconnect loads Appropriate LCD message is shown Master Red Pulse Right hand LED indicates that User has disabled battery EMI heart beat loads provided external relay fitted Appropriate LCD message is shown during Heart Beat Will still charge RanOx Manual Rev 4H1m doc Page July 2009 RanOx BATTERY BOOSTER USER MANUAL 4 2 OUTPUT VOLTAGE CONTROL and INDICATION The output battery voltage shown is that at the end of the standard RanOx cable and its fuse RanOx now adjusts its internal drive to keep this external voltage at the desired value regardless of the output current in absorption and float stages This provides slightly faster absorption stage charging with tighter control of battery voltage during float when external loads are applied Thus most load current will come from RanOx rather than from the battery sustaining higher charge levels 4 3 ADDITIONAL LCD CHARGING PHASE LEGEND As well as the ab
7. actual voltage threshold may be different in your unit as it is a software controlled parameter Case Overtemp electronics are in over temperature condition Unit will stop charging Resetable by restart If this condition persists check to ensure adequate ventilation airflow through fan and case If necessary relocate the unit to improve airflow Case was HOT electronics temperature is was high Unit will automatically reduce charging current to default but otherwise continue charging Resetable by restart If this condition occurs please check to ensure adequate ventilation airflow through fan and case If necessary relocate the unit to improve airflow Bat Overtemp The battery temperature IS over 50 C Bat was HOT The battery temperature WAS over 50 C The unit will stop charging whilst battery temperature is over 50 C This probably indicates the ambient around the battery is too hot Otherwise it could indicate poor battery condition or the charge voltage rate is set too high Note the display of actual and maximum battery temperatures described above Resetable by restart The maximum temperature is cleared by Factory Default Bat Fault This indicates a short or faulty temperature sensor Check the lead for damage It should be unplugged and returned for repair if the fault persists Resetable by restart 7 PHYSICAL OPTIONS 7 1 TEMPERATURE COMPENSATION PROBE When installed this probe provides batter
8. circuit is connected directly to the battery under charge this will waste over half the maximum 25 Amp RanOx output current holding it in BOOST mode This usually results in overcharging and possible permanent battery damage We recommend the optional Battery Temperature Sensor to help protect the battery However RanOx can limit BOOST charging to 2 3 or 4 hour by User selection if loads MUST be permanently connected to the battery Absorption style fridge current typically 13 Amp will rapidly flatten any battery so should not be operated unless fed from the vehicle alternator whilst engine running An optional relay for an absorption fridge connection is shown RanOx will automatically control this relay This fridge feed wire should be AT LEAST 4 square mm size This feed will still drop over 0 5 Volt at 13 Amp with typical cable lengths Fitting of the optional battery load relay will automatically protect the van battery against excessive discharge when stopped camped We recommend that all caravan camper battery loads apart from absorption fridge be through this relay which can be driven by the RanOx as shown This also provides a Master OFF facility to conveniently dis connect all loads which is ideal for travelling charging unless a compressor fridge is fitted to van If desired to run a compressor fridge etc an optional load changeover relay may be fitted which will still drive all van loads whilst driving but not waste RanOx cap
9. if loads MUST be permanently connected to the battery These time limits are NOT available with Option Absorption style fridge current typically 13 Amp will rapidly flatten any battery so should not be operated unless fed from the vehicle alternator whilst engine running An optional relay for an absorption fridge connection is shown in the diagrams RanOx will automatically control this relay This fridge feed wire should be AT LEAST 4 mm size This feed will still drop over 0 5 Volt at 13 Amp with typical cable lengths Fitting of the optional battery load relay shown on the diagrams will automatically protect the caravan camper battery against excessive discharge when stopped camped We recommend that all caravan camper battery loads apart from absorption fridge be through this relay which can be driven by RanOx as shown This also provides a Master Load OFF facility to conveniently disconnect all loads which is ideal for travelling charging unless a compressor fridge is fitted to van If desired to run a compressor fridge etc an optional load changeover relay may be fitted which will still drive all van loads whilst driving but not waste RanOx capacity We recommend the Battery Temperature Sensor to help protect the battery The probe should be fixed to the battery body or either battery terminal with quality adhesive tape or cable tie The small connector should be fully inserted into the socket at the rear of
10. normal operation by Master Load Off restart as described above Major Red fast Major fault with the installation has occurred See the following blink section for details RanOx Manual Rev 4H1m doc Page 8 July 2009 RanOx BATTERY BOOSTER USER MANUAL 4 5 MAJOR FAULT INDICATIONS There are some special Major faults that prevent RanOx from continuing operation If any of these occur the right hand red LED will blink rapidly All charging will cease external relays will release etc The LCD without backlight will advise to See Manual with a Fault number These generally relate to external problems with the installation Note that RanOx will not resume operation after a major fault until the fault is cleared and the booster is restarted This can ONLY be done by holding the FACT switch to restart normal operation which is shown by the welcome message with serial number display Other switch operation is ignored If any of these faults will not clear after completing checking the corrective action suggested below please do not continue to use the unit Remove both input and output fuses and contact your dealer or the factory for assistance number Corrective Action 00016 Input voltage too high gt 16 Volt Car has faulty high external charger from vehicle check disconnect Auxiliary battery voltage too low lt 8 Connected input BEFORE output Volt disconnect and follow
11. reliant but with an ever increasing range of electrical devices As RanOx is a sophisticated product we reserve the right to improve the unit thus the LED behaviour actual LCD text and symbols indicated above may vary with your particular unit Parameter values and Stage behaviour may also be modified to continually keep RanOx the besf mobile DC powered charger available in Australia today 15 CONTACT DETAILS Alan Ransley Director Alan Oxenbould Director RanOx Pty Ltd ABN 28 131 212 952 PO Box 199 Lilydale 3140 Victoria Australia website ranox com au Email info ranox com au Mobile 0400 289 671 RanOx Manual Rev 4H1m doc Page 16 July 2009 RanOx BATTERY BOOSTER WIRING DIAGRAM simple Option 1 2 3 4 This diagram is for information purposes only and is subject to change at any time RanOx Pty Ltd is NOT responsible for any damages direct or indirect arising from or related to the use of this information sheet The Booster should be securely mounted close to auxiliary battery but protected from water dust and vibration The LCD display and switches should be visible accessible Adequate ventilation MUST be provided around and under the RanOx VAN FEED BUSE BREAKER Red RANOX INPUT Red RANOX OUTPUT Positive 7 gt gt m 40A 40A lt 4 for CARAVAN CAMPER APPLICATION a 50 AMP ANDERSON PLUG SOCKET INPUT RanOx OUTPUT Z BOOSTER BATTERY TEMPERATURE SENSOR lt z x UN
12. some of the RanOx M charging stages If the temperature compensation probe is functional an asterisk will appear after the battery V symbol The last character symbol on the lower line indicates the charging stage You should expect to see the unit progress through these stages as it automatically charges your battery following a sophisticated algorithm It may take minutes or hours to advance to completed charge Not all stages apply to any particular situation There are also additional stages Note that the LEDs also indicate the stage as shown below The LCD display backlight automatically turns off after a few minutes It automatically wakes up at any charging stage change or if the FACT switch is briefly pressed LED Explanation Green Pulse RanOx is monitoring input and output voltages ready to heart beat charge when it detects engine running or active input feed Waiting Green Pulse Waiting for I P to stabilise after Low V I P cranking heart beat engine OR waiting for battery to require charging For example solar system may already be charging NEM warmed above 0 PF sane ERP Start confirmed verified A Increasing Yellow blink Smoothly increasing initial current charging until desired Current current is reached Ensures soft start for very flat soft start batteries EE asian Yellow blink Constant current charging until battery reaches boost AU voltage
13. that all caravan camper battery loads apart from absorption fridge be through this relay which can be driven by the RanOx as shown This also provides a Master OFF facility to conveniently dis connect all loads which is ideal for travelling charging unless a compressor fridge is fitted to van RANOX Pty Ltd ABN 28 131 212952 www ranox com au 22 JUL 2008
14. will restart the complete 1 charging sequence A compressor style fridge would normally be fed directly fused or via a separate vehicle feed Please refer to the Installation section and diagrams 6 4 LOW BATTERY PROTECTION RanOx will automatically protect a caravan battery from excessive discharge and possible damage by isolating its loads using an external relay when its voltage drops too low This is typically whilst camping and disconnected from all charging sources Refer to the Battery Load Relay description below for more information The LCD will advise accordingly with LED indication RanOx will still charge this battery if there is an appropriate active supply feed Reset can be tried by selecting Master Load Off then cancelling to resume operation provided the battery has partially recovered 6 5 OTHER DISPLAY MESSAGES Car feed is OFF The booster will automatically reduce the output current when the supply voltage reduces to less than 10 Volt to avoid a low voltage shut down However when the supply voltage under load deteriorates to less than 9 Volt the unit will stop charging Generally this is a cabling problem With option 0 it merely indicates that the engine is off Bat 10V8 Low S This indicates that RanOx thinks the caravan battery voltage is too low to operate any loads It will also remove drive to the appropriate external relay to isolate its loads The
15. Bat 12 5V 00A o Sec steps It will count down taking roughly 45 min to complete a sequence through the normal charging stages Voltage and current for the source and the caravan battery are continuously displayed LED indications will be normal Note that as the source battery becomes discharged RanOx may reduce the charging current if its input reduces below 10 Volt Note that this includes all the voltage drops in the fuses cables and connectors from the source battery to the RanOx Additional protection at 9 Volt input will abort the charge transfer The Transfer can be aborted by executing a Master Load Off On sequence Note that internally the RanOx behaviour is 0 during a Transfer At completion of the transfer time RanOx will complete a restart and restore your normal Option choice Another Transfer can be performed but this would require significant source battery capacity RanOx Manual Rev 4H1m doc Page 11 July 2009 RanOx BATTERY BOOSTER USER MANUAL 6 3 MASTER LOAD OFF FACILITY This provides a convenient Safety facility to isolate all loads lights fans radios accessories etc from a caravan battery before towing or storage It requires an external relay as detailed below To activate or cancel this facility Hold the Less switch and then press the Set switch for gt 7 Sec The LCD will advise accordingly with LED indication at the Heart Beat rate Note that cancelling
16. IT x z OPTIONAL X d gt 4 I Negative EARTH With option 1 4 selected RanOx automatically detects engine running alternator active There must NOT be any other loads sharing either RanOx feed or connected to auxiliary battery in this configuration If loads must be connected to the auxiliary battery during charge then a RanOx controlled load relay is required see other circuits and consult User Manual Suitably rated fuse s or circuit breaker s MUST protect vehicle feeds The booster feed wire should be al least 6 square mm size Any join should be soldered For caravan camper trailer applications a heavy duty connector preferably 50 Amp Anderson style should be used for JUST the RanOx feed The standard trailer plug socket should be used should be used for any fridge feed In line 40 amp fuses provided protect the RanOx input and output However the booster may be DESTROYED by reverse polarity connection of input or output If loads MUST be permanently connected to the auxiliary battery consult User Manual for other suggested circuits RanOx also provides a Master OFF facility to conveniently dis connect all loads If desired to run a compressor fridge etc an optional load changeover relay may be fitted which will still drive all auxiliary loads whilst moving but not waste RanOx capacity RANOX Pty Ltd 28 131 212 952 www ranox com au 17 JUL 2008 RanOx BATTERY BOOSTER WIRING DIAGRAM 4WD MOTORHOME MARINE Option
17. Y LOAD RELAY external RELAY DRIVE NOTES SPECIFICATIONS additional information ONLY PHYSICAL DIMENSIONS EMC COMPLIANCE Radio TV Interference WARNINGS DISCLAIMER REVERSE POLARITY CONNECTION USER ACCESS ACTUAL VOLTAGE CURRENT CHARGING DIAGRAM SUMMARY CONTACT DETAILS SUGGESTED INSTALLATON WIRING DIAGRAMS RanOx Manual Rev 4H1m doc Page 2 July 2009 BATTERY BOOSTER WIRING DIAGRAM SIMPLE Option 1 4 BATTERY BOOSTER WIRING DIAGRAM 4WD MOTORHOME Option 1 4 BATTERY BOOSTER WIRING DIAGRAM 4WD CARAVAN CAMPER Option 1 4 BATTERY BOOSTER WIRING DIAGRAM 4WD CARAVAN CAMPER Option 0 o OO NN OO OO aA FPF WO WO WO W Q Ao AS OY O O aa aan a a R QG WO ND WK NM A 17 18 19 20 RanOx BATTERY BOOSTER USER MANUAL 1 RanOx BATTERY BOOSTER BASIC DESCRIPTION and USE 1 1 BRIEF FUNCTIONAL DESCRIPTION We believe the RanOx Battery Booster delivers the best features for price mobile voltage and current feed to a Caravan Camper Trailer 4WD or Motorhome battery available in Australia today It takes the limited feed from your car engine and boosts it to provide a controlled multi stage regulated supply to this auxiliary battery This provides much higher stored charge prolonging the life of the battery and ensuring maximum capacity to run all those 12 V
18. acity 16 DEC 2008 RanOx BATTERY BOOSTER WIRING DIAGRAM 4WD CARAVAN CAMPER Option 0 This diagram is for information purposes only and is subject to OPTIONAL FRIDGE RELAY change at any time x RanOx Pty Ltd is NOT responsible for any damages direct or indirect FRIDGE FUSE ABSORPTIQN 30 FRIDGE arising from or related to the use of this information sheet 20A The Booster should be securely mounted close to van battery but protected from water dust and vibration The LCD display and switches should be visible accessible Adequate ventilation MUST be provided around and under the RanOx 86 OPTIONAL BATTERY LOAD RELAY 1 RANOX OUTPUT Positive a LOADFUSE2 lt Red 30 gt 40A 5 LOAD FUSE 3 lt gt 85 86 E 86 From E M Ignition Switch BOOSTER L DIODE z lt 50 AME UNIT E ME ae gt EARTH With option 0 the booster MUST connect to the supply battery alternator via a suitable teed relay Failure to do so W result in discharging the supply battery and may damage the booster We recommend at least 40 Amp rating preferably higher particularly if other car loads are fed Suitably rated fuse s or circuit breaker s should protect such feeds The relay energising circuit s should be connected to the ignition circuit so that power is only fed to the RanOx booster and other car loads with the engine running We recommend that a separ
19. anOx output current holding it in BOOST mode This usually results in overcharging and possible permanent battery damage We recommend the optional Battery Temperature Sensor to help protect the battery However RanOx can limit BOOST charging to 2 3 or 4 hour by User selection if loads MUST be permanently connected to the battery Absorption style fridge current typically 13 Amp will rapidly flatten any battery so should not be operated unless fed from the vehicle alternator whilst engine running An optional relay for an absorption fridge connection is shown RanOx will automatically control this relay This fridge feed wire should be AT LEAST 4 square mm size Fitting of the optional battery load relay will automatically protect the auxiliary battery against excessive discharge when stopped camped moored We recommend that all auxiliary battery loads apart from absorption fridge be through this relay which can be driven by the RanOx as shown This also provides a Master OFF facility to conveniently dis connect all loads If desired to run a compressor fridge etc an optional load changeover relay may be fitted which will still drive all auxiliary loads whilst moving but not waste RanOx capacity RANOX Pty Ltd ABN 28 131 212952 www ranox com au 16 DEC 2008 RanOx BATTERY BOOSTER WIRING DIAGRAM 4WD CARAVAN CAMPER Option 1 2 3 4 This diagram is for information purposes only and is subject to OPTIONAL FRIDGE RELAY change at any
20. ate 50 Amp Anderson style plug socket is used for the RanOx booster feed with the standard trailer 7 pin plug socket used for the fridge feed The booster feed wire should be AT LEAST 6 square mm size preferably gt 10 sq mm This feed will still drop over 1 Volt at 30 Amp with typical cable lengths Other loads MAY share this feed provided appropriate cable fuse and relay are used Any join should be soldered In line 40 Amp fuses provided protect the RanOx input and output The booster may be DESTROYED by reverse polarity connection of input or output Under NO circumstances should an absorption fridge circuit be connected directly to the battery under charge This will waste over half the RanOx output current holding it in BOOST mode This results in overcharging and possible permanent battery damage We recommend the optional Battery Temperature Sensor to help protect the battery Absorption style fridge current typically 13 Amp will rapidly flatten any battery so should not be operated unless fed from the vehicle alternator whilst engine running An optional relay for an absorption fridge connection is shown RanOx will automatically control this relay This fridge feed wire should be AT LEAST 4 square mm size This feed will still drop over 0 5 Volt at 13 Amp with typical cable lengths Fitting of the optional battery load relay will automatically protect the van battery against excessive discharge when stopped camped We recommend
21. d DISPLAYS 6 1 AUTOMATIC ENGINE RUNNING DETECTION When any option other than option 0 is selected the RanOx booster will automatically detect when the engine is running or shut down There is a delay in both these cases as the unit verifies the change of state from one to the other This function is monitored throughout all stages of charging by briefly interrupting the charge current about every 5 minutes The RanOx then calculates the resistance of the connecting cable and applies this figure in internal algorithms When RanOx has learnt this value a longer 10 minute interval is used For this option to operate correctly there MUST be NO other connections to the supply feed from the vehicle battery alternator to the booster Any other connection to this circuit will severely affect the operation of the booster and it s charging characteristics This includes excessive discharge of the vehicle battery and possible damage to the receiving battery Please see Installation section and wiring diagrams 6 2 TIMED TRANSFER FACILITY 6 2 1 Description This RanOx facility will efficiently transfer charge when stationary from the vehicle auxiliary battery to the caravan battery During extended stays at an un powered campsite it is possible to run out of charge from the caravan batteries Solar power may reduce this problem for some Users Typically during such an extended stay a User may still make tri
22. engine is running Option 1 4 12 8 Volt If predicted engine alternator below threshold this implies engine is stopped Option 1 4 Maximum charge current Increment of 1 Amp Default of 15 Amp Should be roughly 2596 of auxiliary battery AmpHour capacity Quiescent current RanOx draws roughly this current whilst Off LCD backlight off waiting for engine to start and commence charging During boost stage when current drops below threshold changes to float stage as battery is almost fully charged Threshold rises from 2 5 Amp when Maximum charge current about 10 Amp up to 5 or 6 Amp when Maximum charge current is 25 Amp Lower current applies with functional temperature probe Over Current Margin If current rises above desired level by this margin RanOx will restart Relay Coil Current limit 0 3 Amp Self resetting Polyfuses protect with 18 Volt zeners to damp clamp back emf Fan On Current 5 5 Amp Fan will also operate if case hotter than 53 C whilst charging Fan Off Current 4 5 Amp Fan may also operate for some time after transition to low current Case Temperature high RanOx will reduce current if it reaches this temperature Case Temperature max RanOx will shutdown if it reaches this temperature Battery Temperature 0 50 C RanOx will only charge if auxiliary battery within this range Compensation Factor changes or any switch operated Set Parameters abort timer 10 min If User doe
23. er coil current 300mA relay may be used 8 NOTES The maximum charge current of 25 Amp at maximum boost voltage is only achievable with high quality very low resistance cabling and connectors from the power supply alternator to the booster Preferably there should be no other load on this cable such as fridges as this will lower the input voltage reducing the maximum output current There must NOT be any such loads with Option 1 4 selected The booster may also be forced into low voltage shutdown Before setting voltages and current limit consult your battery supplier for correct charging figures RanOx Pty Ltd accepts no responsibility for these settings Note that there may be occasions when the actual voltage in the Float stage exceeds the preset value if there is another charger eg solar active The RanOx booster will wait cycling between the Off and Wait stages till the battery rest voltage decays to the Float temperature compensated voltage The LCD back light will stay on indicating this condition Note that extreme external charger voltage will result in a Major Fault indication by the RanOx M Also if the vehicle has a high feed voltage say 14 Volt through RanOx to a hot battery which may only require a temperature compensated Float voltage of 13 1 Volt there may be transitory higher output voltage at the Float charging stage RanOx detects this condition and will suspend charging till required
24. eters for your battery and application see page 10 LCD will show the output battery voltage as well as any connected input supply else will report Car Feed Off Battery temperature should have been displayed during Saving Data Connect caravan camper trailer to vehicle if appropriate and ensure input fuse firmly fitted START and idle engine without headlights or air conditioning etc observe RanOx LCD and LEDs monitor charging stage behaviour see page 7 If you have problems carefully read installation section and recheck your work If problems persist contact your installer retailer or the factory Do NOT attempt to open or tamper with RanOx RanOx Manual Rev 4H1m doc Page 6 July 2009 RanOx BATTERY BOOSTER USER MANUAL 4 EXPLANATION of OPERATION Initially and after restart the liquid crystal display will indicate the software version and serial number RanOx 7 624 5 Serial Num 00513 Whilst waiting for the car engine to start you will see similar to one of these displays depending on whether RanOx is using Option 0 or otherwise respectively Car feed is OFF Car 12 5V 00A Bat 12 8V 00A S Bat 12 8V 00A o After the engine has started and the unit has stabilised few minutes it will then display its normal screen similar to one of these Car 12 7V 06A M Car 10 2V 17A Car 12 3V 03A Bat 13 8V 05A c Bat 14 2V 11A b Bat 13 5V 02A f 4 1 CHARGING STAGES The above examples illustrate
25. garded as abuse of the unit 12 3 USER ACCESS There are NO user serviceable parts inside the RanOx booster Opening of the case or tampering with the unit in any way will void any warranty RanOx Manual Rev 4H1m doc Page 15 July 2009 RanOx BATTERY BOOSTER USER MANUAL 13 ACTUAL VOLTAGE CURRENT CHARGING DIAGRAM 30 0 60 25 0 50 20 0 40 RanOx Charging 200Ah Battery Bank from 13V8 Vehicle SHORT feed cable after 46Ah discharge 15 0 30 A o 2 O exe RanOx Battery_Volt exe RanOx Charge Amp es RanOx AmpHour Time elapsed min 0 0 50 100 150 200 250 300 BUDE ens T FLUM E This diagram shows a typical sequence as the RanOx charges a battery through constant current bulk stage to boost voltage absorption stage then holding at float voltage This may take minutes or several hours depending on the battery This graphs actual current and voltage using RanOx to charge a battery bank in an under bonnet application with a fixed 13 8 Volt alternator source Voltage Volt Current Amp On O Capacity Charged Ah 14 SUMMARY The RanOx Battery Booster is proudly designed manufactured and fully supported in Australia by RanOx Pty Ltd It suits the rugged Australian conditions where many travellers wish to spend many days away from mains powered sites being self
26. limit current to default if hot Will temperatures shutdown if further overheated Battery Temperature Adjusts voltage to suit battery temperature for Provides protection against over heating Sensor best capacity and life auxiliary battery Will not charge if battery is too cold Temperature may be viewed Time Limit for Boost User can select 2 3 amp 4 hour limit on boost May be required if static loads on auxiliary charging absorption stage charging When time battery upset charge current monitoring exceeded charging drops to float Master Switch function User can easily isolate loads from auxiliary Uses external relay which also protects battery against auxiliary battery excessive discharge External relay drives Unit provides voltage current measurements Relay functions timing and logic to support optional relay Engine Running transfer loads to wiring engine feed from auxiliary battery Unit incorporates internal FET switches to so that it and charger is not isolate auxiliary battery from car engine loaded Isolate absorption fridges charging feed when stopped Auxiliary battery low isolate this battery to protect against excessive discharge when stopped Also Master Load Off function RanOx Manual Rev 4H1m doc Page 4 July 2009 RanOx BATTERY BOOSTER USER MANUAL 3 INSTALLATION 3 1 RECOMMENDED WIRING and CONFIGURATIONS The RanOx Battery Booster should be securely m
27. m a separate feed when the engine is running but automatically turned off when engine stops See the diagrams for visual explanations The nominal wire colour is brown 7 3 BATTERY LOAD RELAY external The battery load relay coil feed provides two features As shown on the diagrams a suitable relay is connected between the auxiliary battery and its loads such as pumps lights radios etc This relay will isolate these loads if EITHER Master Load Off is selected by User for example before towing to ensure all caravan loads are off OR this battery voltage falls below a lower limit This low battery state is cleared and loads reconnected when its voltage rises satisfactorily unless Master Load Off This is designed to protect the caravan battery during discharge when it may be completely disconnected from the vehicle Reset can be tried by selecting Master Load Off then cancelling to resume normal operation provided the battery has partially recovered The nominal wire colour is blue 7 4 RELAY DRIVE Both the above relay coil drives are active low thus RanOx provides an earth when active Each drive can sink about 300 mA so they can each operate 1 or 2 suitable coils in parallel which are powered from nominal 12V RanOx provides over current protection and back emf damping to these coil drives Suitable relays are Jaycar SY 4068 30 Amp SPST SY 4070 30 Amp SPDT and SY 4074 60 Amp SPDT One single high
28. mm as any losses are wasted We recommend that a separate 50 Amp Anderson style plug socket is used for the RanOx booster feed with the standard trailer 7 or 12 pin plug socket used for the fridge feed The booster feed wire should be AT LEAST 6 size preferably over 10 mm This feed will still drop at least 1 Volt at 30 Amp with typical cable lengths Any join should be soldered In line 40 Amp fuses provided protect the RanOx input and output The booster may be DESTROYED by reverse polarity connection of input or output Check that yours is correct BEFORE connecting Note that the caravan camper Anderson plug is NOT live when it is disconnected from the vehicle Thus if it becomes dislodged from the vehicle and damaged there is no current flow from the auxiliary battery back to this connector This also prevents damage from malicious mischief Under NO circumstances should an absorption fridge be connected directly to the battery under charge with option O selected It is highly undesirable with other option choices Direct connection wastes over half the RanOx output current holding it in BOOST stage mode This may result in overcharging and possible permanent battery damage We recommend the Battery Temperature Sensor to help protect RanOx Manual Rev 4H1m doc Page 5 July 2009 RanOx BATTERY BOOSTER USER MANUAL the battery However RanOx can limit BOOST charging to 2 3 or 4 hour by User selection
29. nt capability may be restored provided the cause of the high temperature has been eliminated by a restart This be done by selecting Master Load Off then cancelling to resume normal operation Completing a Set Parameter sequence will also recheck fault conditions Note that actual and maximum battery temperatures are displayed at the completion of a Set Parameter sequence See paragraph 4 5 below for MAJOR fault conditions Faut LED Explanation Bat Fault This indicates a short or faulty temperature sensor Charging is stopped Check the lead for damage It should be unplugged and returned for repair if the fault persists Over Temp Case or Battery IS Over Temperature Charging is stopped Must be manually acknowledged and cleared However if they cool message changes to was HOT and charging resumes as detailed below Hot und Battery Temperature WAS HIGH Charging has resumed as normal A warning message remains on the LCD which must be manually acknowledged and cleared Hot uu Case Temperature WAS HIGH RanOx has resumed charging with default current to reduce the internal heat A warning message remains on the LCD which must be manually acknowledged and cleared Low Red blink Low Voltage Protection when the auxiliary battery is so flat Voltage that loads should be disconnected to protect it from damage RanOx provides a relay drive for this function You may try to restore
30. olt devices at your remote campsite It suits a variety of Lead acid battery types flooded conventional car type sealed gel type deep cycle type AGM type etc It will provide up to 25 Amp of CONTROLLED charging current for these batteries provided that adequate car engine supply is available In addition it will act to protect this auxiliary battery during discharge by disconnecting loads before low voltage is reached 1 2 SIMPLIFIED INSTALLATION In its simplest installation the RanOx Battery Booster has only three connections e Vehicle feed NOT shared by any other load protected by fuses etc e Boosted output and earth connecting directly to the caravan battery sheathed cable The later installation section provides details and restrictions particularly for applications using more of the RanOx Battery Booster advanced features 1 3 SIMPLIFIED OPERATION The RanOx can be simply left with its factory default parameter values for most batteries It will automatically detect engine run status and appropriately charge the caravan battery The LCD and LEDs will advise of charge state stage with vehicle and caravan battery voltage and current displayed appropriately If you wish to have more detailed understanding of RanOx please review the rest of this User manual and its diagrams 1 4 PRECAUTIONS Please read and follow the start up procedure described at the end of the installation section Do not c
31. onnect power from ANY battery or other power source to the RanOx without CAREFULLY checking polarity Incorrect connection will DESTROY sections of RanOx and will void your warranty RanOx Manual Rev 4H1m doc Page 3 July 2009 RanOx BATTERY BOOSTER USER MANUAL 2 RanOx BATTERY BOOSTER FEATURES and DESCRIPTION 2 1 FULL FEATURE TABLE The following table outlines the significant features of the RanOx Battery Booster from August 2008 Wide Ranging Input From 9 to 14 Volt feed Any van fridge should be operated by this voltage input feed BEFORE the booster The unit will automatically drive a suitable relay to control a fridge Engine running detection Inbuilt detection of engine running by Avoids need for ignition operated relay or prediction of alternator voltage Automatically other similar device Must not have other compensates for cable connector resistance loads on THIS feed eg fridge in car with this option selected Regulated stable Output Output is regulated to provide constant current Mode Stage is automatically selected to suit Voltage or Current or boost float voltage regardless of input auxiliary battery condition Output cable variations voltage drop compensated Rugged Input Output Protected against Unit automatically limits current drawn from circuitry ignition voltages car engine to about 30 Amp provided wiring short circuit is adequate In line 40 Amp fuses further overloaded output
32. ounted close to caravan camper battery but protected from water dust and vibration Typically this would be inside the front locker The LCD display and switches should be visible accessible with locker door open Adequate ventilation MUST be provided around and under the RanOx The unit can be mounted in any orientation EXCEPT front down as this would reduce essential cooling air flow Do NOT drill into the case or otherwise tamper with RanOx Do NOT lengthen mounting screws It must NOT be located under the vehicle bonnet This location is too hot dusty and wet The booster should be located as close as possible to the receiving battery to avoid losses from the booster to this battery If the supplied output lead needs to be extended ensure that high quality joins to large well over 10 mm cross section cable are used Please refer to the suggested wiring diagrams for connection information These diagrams are for information purposes only and are subject to change at any time RanOx Pty Ltd is NOT responsible for any damages direct or indirect arising from or related to the use of this information The booster MUST be connected to the supply battery alternator via a heavy duty feed as shown We recommend at least 40 Amp rating preferably higher particularly if other loads eg absorption fridge share this feed Suitably rated fuse s or circuit breaker s MUST protect all feeds It is VERY important that this feed all the way f
33. ove charging stage information which is indicated by the symbol on the lower line and the LEDs RanOx has some other intermediate phases These are indicated by the last character symbol on the upper line as explained below Upper Symbol The vehicle feed voltage is low 10 Volt so charging has been reduced The vehicle feed is being limited near the 30 Amp maximum Explanation The battery charging current is being controlled The engine status is being verified Please note that this information is provided for those Users who wish to understand the details of the RanOx operation It is not required knowledge to install and operate the unit During the verify phase RanOx pauses its charging so that the engine voltage may be verified This 30 Sec pause repeats every 5 minute only during options 1 4 or if RanOx suspects that the engine has stopped RanOx learns the cable resistance between itself and the alternator to reliably predict the engine voltage regardless of the current being drawn from the vehicle When RanOx has learnt this value a longer 10 minute interval is used 4 4 FAULT INDICATIONS The right hand LED indicates other conditions mainly faults Some conditions stop all charging However RanOx will tolerate its case becoming hot by automatically reducing the current The LCD will provide more detailed information in all cases With Case HOT condition the full curre
34. protect over charging over heating REVERSE polarity will damage unit faulty external chargers Transfer facility with Timer Timed 45 min transfer of charge from 4WD User may manually start stop Transfer and Low Voltage Input auxiliary battery to caravan with automatic Nominal cut out at 9 Volt at the RanOx protection excessive discharge prevention Used with Booster will reduce its output current when extended campsite stays input voltage is below 10 Volt to avoid premature shutdown Sophisticated multi stage prepares battery with constant current or suits deep cycle batteries which have charging system bulk charge stage limited initial current absorption charge at boost voltage typically near 15 Volt for maximum charging till current reduces below threshold held at float to sustain capacity typically near 13 5 Volt PLUS many other intermediate stages modes LCD display with switch Provides two line detailed parameter display Changes are restricted to sensible values controls and LED and adjustment Altered parameters are remembered without indicators User may alter basic parameters maximum power current boost and float voltage Extensive diagnostic indications are provided User can select option and reset to Factory for abnormal conditions Default Automatic Cooling Fan Fan to cool unit only operates as required Unit operates in high ambient conditions normally at higher currents and or Unit will
35. ps in their vehicle For example fire wood shopping touring etc This will normally ensure that the vehicle cranking and auxiliary battery if fitted are charged RanOx can efficiently transfer this charge from the auxiliary battery into the van battery whilst boosting the voltage to the desired level This top up can significantly extend the possible powered duration of a stay without requiring solar power or generators etc 6 2 2 Connection The vehicle or some other portable battery source must be connected to the RanOx typically by connecting the caravan Anderson plug into the vehicle outlet This outlet must be powered NOT fed through an ignition operated relay or smart solenoid etc A portable battery pack should be connected to the caravan inlet if that is to be the transfer energy source All these cables must be very heavy duty as losses during Transfer can NOT be recovered as there is no alternator to just supply a bit more power For example 10 metre of 4 mm wastes 40 Watt of energy at 30 Amp 6 2 3 Operation This special facility is invoked by using Set Parameters to select Option 5 Then complete the Set sequence As soon as RanOx has finished Saving Data it will commence the special Transfer charging The first LCD line will indicate the approximate time remaining in tens of Seconds 254t12 7V 00A This time replaces the Car word The t is to indicate Transfer time in ten
36. rom alternator cranking battery through to RanOx be high quality All joins should be inspected and soldered if necessary Our experience suggests that many vehicle and caravan installations are FAR BELOW the required standard Please check and inspect to ensure your feed can deliver over 30 Amp to the RanOx at above 11 Volt Suitable high current circuit breakers are Jaycar SF 2265 70 Amp or SZ 6000 twin 60 Amp For option 0 the relay energising circuit s MUST be connected to the ignition circuit so that power is only fed to the RanOx booster and any absorption fridge with the engine running Failure to do so WILL result in discharging the supply battery Other loads MAY share this feed although this will reduce overall efficiency and lower available charging current With option 1 4 selected RanOx automatically detects engine running alternator active For these options RanOx requires a dedicated supply feed from the vehicle battery alternator for correct operation Any other connection to this circuit will severely affect the operation of the booster and it s charging characteristics This includes excessive discharge of the vehicle battery and possible damage to the receiving battery Note that the Transfer facility described later requires the same dedicated live feed as required for Option 1 4 It should not be switched by a relay smart or otherwise It is MORE important to have HEAVY cabling well over 10
37. s bonded to a good chassis ground as close as possible to the auxiliary battery If necessary reorient or relocate the receiving antenna away from the booster and its cabling Consult your dealer or the factory for further advice 12 WARNINGS 12 1 DISCLAIMER This booster is designed specifically for use between a vehicle and a caravan camper trailer It may also be used with an auxiliary battery in a 4WD or Motorhome If installed and programmed correctly it will compensate for cable losses and or low alternator voltage to fully charge then float a recreational battery with the correct voltage and current for that battery Using this booster for any other purpose may cause damage to the booster and or other appliances Please consult your dealer or the factory to discuss many other possible applications This product is built from quality components using approved engineering design techniques available at the time of construction however the designer assembler and dealer will not be held in any way responsible for any damages direct or indirect arising from or related to this product Although we have made every endeavour to provide accurate and up to date information in this manual and its diagrams there may be unintentional errors or omissions 12 2 REVERSE POLARITY CONNECTION Take particular care when installing or connecting batteries as the RanOx booster will be DESTROYED by reverse polarity connection This is re
38. s not complete a Set Parameter sequence within this time RanOx will abort the sequence and automatically return to normal operation r Engine Verify timer 5 min Charging pauses at this interval with options 1 4 to verify that O engine is still running Longer interval applies when system 10 min stabilises and cable resistance has been learnt Total time for Transfer facility for all charging stages Charge current threshold with probe RanOx Manual Rev 4H1m doc Page 14 July 2009 RanOx BATTERY BOOSTER USER MANUAL 10 PHYSICAL DIMENSIONS The RanOx booster is housed inside an extruded alloy case as shown in the title page photographs lts approximate dimensions are 120 105 55 mm length width height Mounting feet occupy an additional 20 mm each side Extra space must be allowed for its switches leads etc as well as considerable clearance for the air flow required Its mass is approximately 1 kg We reserve the right to alter this case and any dimensions as required to suit our high standards A drilling guide template is provided for your convenience 11 EMC COMPLIANCE Radio TV Interference The RanOx battery booster complies with the requirements of CSIPR 22 Class A N21629 However if you experience any apparent interference from this device try re routing input output cables away from sensitive electronic devices and their cabling Ensure that the negative battery terminal i
39. tery s Ah rating eg for a 100 Ah battery set max current at 25 Amp For battery capacity over 100 Ah select 25 Amp Range 5 to 25 in 1 Amp steps Factory default is 15 Amp The charging is held approximately constant near this current during the initial bulk phase Actual output may vary by about 1 Amp around this nominal current Note that this nominal current will be automatically reduced with a very flat battery or if the case becomes hot If a sudden large load is placed upon the auxiliary battery during this stage the RanOx M will restart itself to protect against excessive over current Briefly pressing the Set again displays Saving Data This preserves data in non volatile memory If the temperature probe is fitted and functional the actual and maximum battery temperatures will also be displayed eg 25 34 C The unit then reverts to one of the initial displays and begins the charging sequence Any fault conditions will be rechecked Once set there is no need to change these parameters again unless you change batteries Note that Factory Default values may be restored to option and all these parameters by pressing the FACT switch from within this sequence The unit will advise accordingly This will clear the maximum battery temperature and force a complete restart of the 1 RanOx Manual Rev 4H1m doc Page 10 July 2009 RanOx BATTERY BOOSTER USER MANUAL 6 ADDITIONAL OPERATIONS an
40. the RanOx The small lead should be protected against physical strain and damage If you are still have doubts about your installation reread this manual and review the circuit diagrams Your dealer or factory will also assist you It is much better to ensure an optimum installation than to proceed quickly and regret later 3 2 START UP SEQUENCE Check polarity of your power sources BEFORE making any connections Do NOT disconnect output battery positive or negative whilst input feed battery is connected Do NOT connect case to ANY power source The correct RanOx power up sequence is to FIRST connect the output battery negative black lead in sheath then positive red fused lead which is in sheath with black lead o may wish to remove the output fuse whilst you connect o you Will notice a small spark when connect fuse or terminal RanOx should start up and be alive without ANY fault code ifthe unit is not alive or there are error codes do NOT proceed o check wiring fuse and consult pages 8 and 9 for remedial action If RanOx is alive with normal display should report Car Feed Off THEN connect up input wiring may wish to remove the input fuse whilst you connect in an under bonnet application in caravan camper trailer application this is not required as you should not be connected to vehicle Connect temperature probe to rear socket RanOx may re start Set the appropriate param
41. time x RanOx Pty Ltd is NOT responsible for any damages direct or indirect FRIDGE FUSE ABSORPTIQN 30 FRIDGE arising from or related to the use of this information sheet 20A The Booster should be securely mounted close to van battery but protected from water dust and vibration i isibl ible FRIDGE ETC FEED FUSE 7 PIN TRAILER PLUGISOCKET The LCD display and switches should be visible accessible VE 0 LOAD FUSE 1 FEED FUSE A LOAD FUSE2 lt O EN 2 LOAD FUSE 3 lt gt BOOSTER 50 AMP ANDERSON PLUG SOCKET UNIT TWIN sheathed cable Black Y CAR BATTERY EARTH RANOX Pty Ltd ABN 28 131 212 952 www ranox com au With option 1 4 selected RanOx automatically detects engine running alternator active There must NOT be any other loads sharing the RanOx feed in this configuration Suitably rated fuse s or circuit breaker s MUST protect vehicle feeds We insist that a separate preferably 50 Amp Anderson style plug socket is used for the RanOx booster feed with the standard trailer 7 pin plug socket used for the fridge feed The booster feed wire should be AT LEAST 6 square mm size preferably gt 10 sq mm This feed will still drop over 1 Volt at 30 Amp with typical cable lengths Any join should be soldered In line 40 Amp fuses provided protect the RanOx input and output The booster may be DESTROYED by reverse polarity connection of input or output If an absorption fridge
42. y temperature to the RanOx M which adjusts the charge voltage to the optimum value for the battery temperature It may also reduce the threshold current for the bulk to float stage transition This helps to maximise charge capacity RanOx Manual Rev 4H1m doc Page 12 July 2009 RanOx BATTERY BOOSTER USER MANUAL As charging figures recommended for batteries by the manufacturer are generally for a temperature of near 20 C if the temperature compensation probe is used you may notice a slightly different charge voltage to that selected This is correct operation i e the lower the temperature the higher the charge voltage When temperature compensation probe is functional an asterisk will appear after the battery V symbol on the LCD The actual and maximum battery temperatures eg 25 34 C are shown during saving data after a Set Parameter or Factory Default sequence If the battery is colder than O C charging will be delayed till the battery warms If the unit is used without the temperature compensation probe then the indicated charge voltages will be as you have selected Charge may however not be the optimum nor will battery temperature protection be available 7 2 ENGINE RUN RELAY external When RanOx has detected engine running Option 1 4 or an active vehicle feed Option 0 it will drive an external relay coil which can divert control loads For example an absorption fridge can be operated fro
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