PowerMax PM3 - User Manual

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AC to DC Converter/Charger

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

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.

120 VAC

receptacle needs to be located within 36 inches of the Converter/Charger to supply power.

Ele

ctrical consi

deration 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.

7. Never Leave the PowerMax PM3-XX unattended when plugged in.

8. All PM3 Products must

be installed by a certified electrician.

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.

SAFETY ALERT

120 VAC

is present. This Converter/Charger is designed to convert

120 VAC

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 Possible Injury or Death

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.

WARNING – Avoid Personal Injury or Product Damage

6. THE FAN WILL NOT RUN ALL THE TIME. THE FAN RUNS ONLY WHEN NEEDED.

Need help?

Do you have a question about the PowerMax PM3 and is the answer not in the manual?

Summary

Installation and Maintenance

General Safety and Warnings

General safety alerts and warnings regarding electrical hazards, flammable liquids, and proper installation.

Key Installation Procedures

Essential installation steps: disconnecting power, selecting location, mounting, and electrical connections.

Operational Notes and Requirements

Important notes on fan operation, unattended use, and mandatory installation by a certified electrician.

Converter Operation and Features

AC Connection Safety

Safety precautions for connecting the 120 VAC power source and circuit breakers before installation is complete.

12 VDC Wiring Requirements

Guidelines for correct wire gauge and terminal connections for the 12 VDC output.

3 Stage Charging Description

Explanation of the automatic three-step charging system: Boost, Normal, and Storage modes.

Adjusting Fixed Voltage

Procedure for adjusting and setting a fixed output voltage for the charging system.

Testing and Troubleshooting

Testing Converter Output

Steps to test the converter's output voltage under no-load and load conditions using a multimeter.

Battery Connection and Maintenance

Connecting the battery and checking fluid levels for regular maintenance.

Hi-Pot Testing Safety

Warning against performing Hi-Pot testing on DC wiring with the converter connected.

Troubleshooting Common Issues

Table detailing possible causes and solutions for common converter issues like no output or cycling.

Legal and Usage Information

Two Year Limited Warranty

Details of the two-year limited warranty, including remedy, limitations, and required installation by an electrician.

General Disclaimer

Disclaimer on product improvements, information accuracy, and user responsibility for product use.

Product Use Limitations

Restrictions on using products in critical applications like life-support or nuclear facilities.

Summary

Installation and Maintenance

General Safety and Warnings

General safety alerts and warnings regarding electrical hazards, flammable liquids, and proper installation.

Key Installation Procedures

Essential installation steps: disconnecting power, selecting location, mounting, and electrical connections.

Operational Notes and Requirements

Important notes on fan operation, unattended use, and mandatory installation by a certified electrician.

Converter Operation and Features

AC Connection Safety

Safety precautions for connecting the 120 VAC power source and circuit breakers before installation is complete.

12 VDC Wiring Requirements

Guidelines for correct wire gauge and terminal connections for the 12 VDC output.

3 Stage Charging Description

Explanation of the automatic three-step charging system: Boost, Normal, and Storage modes.

Adjusting Fixed Voltage

Procedure for adjusting and setting a fixed output voltage for the charging system.

Testing and Troubleshooting

Testing Converter Output

Steps to test the converter's output voltage under no-load and load conditions using a multimeter.

Battery Connection and Maintenance

Connecting the battery and checking fluid levels for regular maintenance.

Hi-Pot Testing Safety

Warning against performing Hi-Pot testing on DC wiring with the converter connected.

Troubleshooting Common Issues

Table detailing possible causes and solutions for common converter issues like no output or cycling.

Legal and Usage Information

Two Year Limited Warranty

Details of the two-year limited warranty, including remedy, limitations, and required installation by an electrician.

General Disclaimer

Disclaimer on product improvements, information accuracy, and user responsibility for product use.

Product Use Limitations

Restrictions on using products in critical applications like life-support or nuclear facilities.

The PowerMax PM3 series of AC to DC Converter/Chargers are designed to convert 120 VAC to 12 VDC and provide low-voltage power for charging on-board 12 VDC batteries. These units are "switch mode" type converters, designed for maintenance-free operation with no user-serviceable components. The power output is current-limiting by design.

Function Description

The primary function of the PowerMax PM3 Converter/Charger is to supply stable 12 VDC power from a 120 VAC source. This makes it suitable for various applications where a reliable DC power supply is needed, particularly for charging 12 VDC batteries. The device is designed to be installed in a vehicle or device and provides a continuous DC power source while also managing battery charging.

Usage Features

Installation: The unit can be mounted on any interior surface not exposed to direct weather. Proper ventilation is crucial, requiring a minimum of 1 inch of free air space at each end of the unit to allow for adequate cooling airflow. It is important to avoid mounting the unit in compartments designed for storing batteries or flammable liquids. The mounting process involves using standard fasteners through provided flanges. Electrical connections require a 120 VAC receptacle within 36 inches for power supply and proper wiring to the 12-volt DC distribution panel and batteries. All PM3 products must be installed by a certified electrician.
Safety Precautions: Before installation, it is critical to disconnect the battery POS (+) wire at the battery end. During AC connection, the 120 VAC power source AC circuit breaker(s) must be in the "off" position until installation is complete. The unit should never be stored in compartments with flammable liquids. The fan operates only when needed, indicating an efficient cooling system. The PowerMax PM3-XX should never be left unattended when plugged in.
Wiring: For 120 VAC connection, an 8 AWG minimum size copper wire should be used to attach from the vehicle/device chassis to the Converter/Charger Bonding Lug. The attached power cord connects firmly to the 120 VAC receptacle. For 12 VDC wiring, a minimum of 8 AWG size copper wire is recommended. The terminal marked "+" or "POS" is for the RV 12 VDC positive connection, and the terminal marked "-" or "NEG" is for the RV 12 VDC negative connection. The 12 VDC output wiring does not require over-current protection due to the Converter/Charger's current limiting design, but all electrical connections must comply with the appropriate NEC code.
Three-Stage Charging Option: This optional feature provides an automatic charging system with three distinct stages to optimize battery life and performance:
1. Boost Mode: A fast charge to rapidly bring a drained battery up to full voltage.
2. Normal Mode: A standard charge to bring the battery to a full charge at a safe rate, prolonging battery life, and providing power for 12V lighting and appliances.
3. Storage Mode: A trickle charge to maintain battery freshness during periods of low load inactivity. The charger automatically transitions between these modes based on changing conditions.
Adjust Fixed Voltage: The unit initially operates in three-stage charging mode. To adjust to a fixed voltage, switch A is moved to "Adjust Fixed Voltage." Switch B can then be gently moved to adjust the voltage from 13V to 16.5V, providing a fixed output voltage. To return to three-stage charging, ensure the voltage is set to 14.6V, then move switch A back to "Three stage charging." The unit will then run at 14.6V for approximately 0.5 hours, 13.6V for almost 12 hours, and then 13.2V. The voltage values in three-stage charging will adjust according to the fixed voltage set.

Maintenance Features

Troubleshooting: The manual provides a troubleshooting guide to diagnose common issues. Before removing or replacing the Converter/Charger, specific checks should be performed:
- Disconnect AC power from the vehicle/device.
- Disconnect wiring and the battery from the Converter Positive (+) output terminal.
- Reconnect AC power to energize the Converter.
- Use a voltmeter to measure the voltage at the Converter's (-) and (+) Output terminals. If the voltage reading is between 13 VDC and 14 VDC (typically 13.6 VDC), the Converter is considered OK. Otherwise, refer to the troubleshooting table.
Common Issues and Solutions:
- No 12 VDC output: Possible causes include 120 VAC not connected or the AC circuit breaker being in the "off" position, blown reversed battery fuses (due to reversed battery wiring connections), severe overload or shorted load, or internal Converter/Charger failure.
- Converter cycles On & Off: This could be due to inadequate or blocked fan airflow (requiring the 1-inch minimum free air space), or internal Converter/Charger failure.
- Reversed Battery fuses blown: Indicates reversed battery wiring connections.
- 12 VDC output is too low: Possible causes are a defective battery with bad cells, an attached load exceeding the Converter/Charger's rating, or internal Converter/Charger failure.
Battery Maintenance: When continuously connected to any charging source, batteries will "Gas" and lose some fluid. It is important to regularly check the fluid level of batteries.
Testing: To test the Converter/Charger, first disconnect all loads and the battery by removing all 12 VDC connections from the (+) or POS terminal. Then, attach a multimeter between the positive and negative terminals of the Converter/Charger. Energize the 120 VAC converter circuit and measure the output voltage, which should read 14.6 +/- 0.2 VDC. After adding 12 VDC load connections (up to 2/3 of the rated capacity), the voltage should remain approximately the same as at no load.
Hi-Pot Testing: For vehicle/device manufacturing facilities only, it is crucial NOT to Hi-Pot DC wiring with the Converter/Charger connected to the vehicle/device wiring to prevent serious injury or damage.

PowerMax PM3 Specifications

General

Brand	PowerMax
Model	PM3
Category	Battery Charger
Language	English