CTEK D250SA, SMARTPASS 120 - Dual Battery Charger Manual

CONGRATULATIONS

This charger is included in a series of professional chargers from CTEK SWEDEN AB and represents the latest technology in battery charging. With the CTEK D250SA and SMARTPASS 120 you can be sure of getting maximum performance from your dual battery system.

SAFETY

CALIFORNIA PROPOSITION 65

This product contains chemical known to the state of California to cause cancer or reproductive toxicity.

• The D250SA and SMARTPASS 120 have been developed for 12V lead-acid batteries. Do not use the unit for any other type of battery.
• Wear protective goggles when connecting and disconnecting batteries.
• Battery acid is corrosive. Rinse with plenty of water immediately if you get acid on your skin or in your eyes. Get medical assistance.
• Never use a charger with damaged electric cables. Check that the cables have not been damaged by hot surfaces, sharp edges or in any other way.
• Explosive gases are generated while lead-acid batteries are being charged. Avoid any sparking near the battery. Use in a well-ventilated location.
• Never place the charger above the battery, and avoid covering the charger during charging.
• Disconnect the battery terminal posts before installing.
• The D250SA and SMARTPASS 120 are not spark-free.
• The installation must include a fuse in accordance with the recommendations in the table "CABLE AND FUSE RECOMMENDATIONS".

The D250SA and SMARTPASS 120 are not protected against reversed polarity.

Remember that all installations in boats must comply with ISO 10133!

1. The cabling from the batteries must have fuses near the batteries.
2. The batteries must be securely fastened in a ventilated space.
3. The cabling must be run through pipe ducting, separately from 230V/110V wiring (mains power), or secured by clips at every 30 cm/1 ft.
4. Cabling in the engine compartment must be temperature rated at 700C/ 1580F.

D250SA

• The D250SA is a DC to DC battery charger for a dual battery system with a starter battery and a service battery.
• The D250SA charges the service battery either from an alternator or from a solar panel, or from a combination of both.
• The D250SA separates the batteries in a dual battery system and thereby replaces, for example, a separation relay, VSR (Voltage Sensitive Relay), diode isolator or a mechanical battery selector.
• The D250SA can be used on its own or in combination with SMARTPASS 120. In combination, the D250SA and SMARTPASS 120 can charge at up to 140A.

SMARTPASS 120

FUNCTION INDICATIONS

	D250SA	Explanation
1		The service battery is being charged by the alternator.
2		The service battery is being charged by the solar panel.
3		The service battery is being charged by both the alternator and solar panel.
4		The service battery is fully charged. The service battery is being trickle charged by the solar panel.
5		Current saving mode, no charging in progress.
	SMARTPASS 120	Explanation
1		Current from alternator to service battery and consumers. Current from service battery to consumers.
2		Current from alternator to service battery and consumers.
3		Current from alternator to consumers. The service battery is charged by the D250SA.
4		Trickle charging of the starter battery from the service battery.

CABLE AND FUSE RECOMMENDATIONS

					MIN. CABLE SIZE
UNIT		CABLE			0.5 m 2 ft	1 m 3 ft.	2 m 6 ft.	5 m 15 ft.	10 m 30 ft.	FUSE
D250SA					4 mm / 2 AWG12	4 mm / 2 AWG12	4 mm / 2 AWG12	6 mm / 2 AWG10	10 mm / 2 AWG8	30A
	SMARTPASS 120				4 mm / 2 AWG12	6 mm / 2 AWG10	10 mm / 2 AWG8			30A
					4 mm / 2 AWG12	4 mm / 2 AWG12	4 mm / 2 AWG12	4 mm / 2 AWG12	4 mm / 2 AWG12
		Connector plate*			4 mm / 2 AWG12	6 mm / 2 AWG10	10 mm / 2 AWG8	10 mm / 2 AWG8	10 mm / 2 AWG8
					35 mm 2 AWG2	35 mm 2 AWG2	35 mm 2 AWG2	50 mm 2 AWG1	50 mm 2 AWG1	300A
					35 mm 2 AWG2	35 mm 2 AWG2	35 mm 2 AWG2			300A

*If the D250SA and SMARTPASS 120 are installed in different locations and the accompanying connector plate is not used, please follow the recommendations in the table.

INSTALLATION

1. Install the apparatus on a smooth surface where it can be firmly secured and where it is not exposed to fuel, oil or dirt. To obtain the correct distance, start by fitting the two units together with the accompanying connector plate (see Figure 3) before they are finally fastened to the smooth surface.
2. Secure the apparatus with, for example, M4 or ST4.2 screws at each corner (see Figure 1).
3. Before connecting the cables, ensure that the negative terminal post on the battery is not connected.
4. Connect the cables to the apparatus connections by securing screws (M8) (see Figure 2). Use an Allen key - tightening by hand without a tool is not enough.
5. Use tape (see Figure 4) to secure the temperature sensor to a clean flat surface above the service battery. Position the sensor as close to the positive terminal post as possible.
   
   
6. Connect the battery negative terminal post.

RECOMMENDED TIGHTENING TORQUES

DIMENSIONS

SETTINGS D250SA

Smart alternator cable (red)	Type of alternator	AGM cable (black)	Charging voltage
Not connected	Conventional alternator	Not connected	14.4V
Connected	Smart alternator	Earth	14.7V

SYMBOLS

Fuse		See "CABLE AND FUSE RECOMMENDATIONS"
Flashing lamp		Continuously lit lamp
Solar panel		Non critical consumer
Alternator		Critical consumer

INSTALLATION EXAMPLES

Solar panel

PREREQUISITES
Solar panel capable of charging a 40–300Ah service battery. The D250SA uses MPPT (Maximum Power Point Tracker) to maximise the power from a solar panel.
TIP 1
Do not connect two solar panels in series. Max. input voltage 23V.

*See "CABLE AND FUSE RECOMMENDATIONS"

Small service battery

PREREQUISITES
A dual battery system where the D250SA charges a 40–300Ah service battery from a generator which also charges a starter battery. It is advantageous to use this installation when:

• The alternator is unable to deliver the desired charging voltage.

TIP 2
If the alternator has external voltage detection for the service battery, the voltage detection wiring must be connected to the starter battery.
TIP 3
Complement the D250SA with a SMARTPASS 120 if the service battery capacity is greater than 100Ah or has parallel consumption while charging is in progress. This reduces the charging time.

*See "CABLE AND FUSE RECOMMENDATIONS"

Small service battery and solar panel

PREREQUISITES
A dual battery system where the D250SA charges a 40–300Ah service battery from a solar panel, an alternator, or both which also charge a starter battery.
It is advantageous to use this installation when:

• The alternator is not able to deliver the desired charge voltage.
• Charging from a solar panel.
  See also tips 1, 2 and 3.

*See "CABLE AND FUSE RECOMMENDATIONS"

Service battery with parallel consumers

PREREQUISITES
A dual battery system where the SMARTPASS 120 charges a 28–800Ah service battery from a alternator which also charges a starter battery. It is advantageous to use this installation when:

• The alternator is able to deliver the desired charging voltage.
• The service battery capacity is greater than 100 Ah.

Large service battery with parallel consumers

PREREQUISITES
A dual battery system where a D250SA together with a SMARTPASS 120 charges a 100–800Ah service battery. Current is supplied from a solar panel and/or an alternator. The starter battery is charged from an alternator. It is advantageous to use this installation when:

• The alternator is not able to deliver the desired charging voltage.
• The service battery capacity is greater than 100Ah.
• Parallel consumption takes place during charging. By connecting the consumers to the Output Consumers on the SMARTPASS 120, the service battery will be able to charge without parallel consumption and the consumers will instead be supplied with current from the alternator.

• The service battery shall be protected against deep discharge. Connect non-critical consumers to the Output Consumers on the SMARTPASS 120. Connect critical consumers directly to the service battery. SMARTPASS 120 does not in that case switch off the critical consumers when the service battery is completely discharged.

TIP 4
Connect the cabling from the starter and service batteries respectively to the SMARTPASS 120 and not to the D250SA. See also tips 1, 2 and 3.

*See "CABLE AND FUSE RECOMMENDATIONS"

Connect an AC/DC charger

PREREQUISITES
A dual battery system where there is a 230/110V charger and a D250SA that, together with a SMARTPASS 120, charge a service battery with a capacity of 150–800Ah. Current is supplied from a solar panel and/or an alternator to the service battery. The starter battery is charged from an alternator.
It is advantageous to use this installation when:

• The charge from the alternator while it is charging (engine running) is not enough, so it has to be supplemented by a 230/110V charger.
• The alternator is not able to deliver the desired charge voltage.
• The service battery capacity is greater than 150Ah.

TIP 5
Connect a 230/110V charger to the starter battery if it needs charging. In that case both the starter and service batteries will be optimally charged from the 230/110V charger.
TIP 6
Heavy current consumers (more than 80A) must be connected directly to the service or starter battery.
See also tips 1, 2, 3 and 4.

*See "CABLE AND FUSE RECOMMENDATIONS"

D250SA CHARGING PROGRAM

1. DESULPHATION
   Detects sulphated batteries. Pulsing current and voltage, removes sulphate from the lead plates of the battery restoring the battery capacity.
2. BULK
   Charging with maximum current until approximately 80% battery capacity.
3. ABSORPTION
   Charging with declining current to maximize up to 100% battery capacity.
4. FLOAT
   Maintaining the battery voltage at maximum level by providing a constant voltage charge.
5. PULSE
   Maintaining the battery at 95–100% capacity. The charger monitors the battery voltage and gives a pulse when necessary to keep the battery fully charged.

D250SA FAULT INDICATIONS

	Reason: The apparatus and/or the service battery has a temperature that is too high. Recommendation: Consider moving the apparatus and/or the service battery to a cooler location.
	Reason: The service battery has a connection problem. Recommendation: Check the connections of the service battery and its fuse.
	Reason: The service battery has a connection problem. Recommendation: Check the connections of the service battery and its fuse.
	Reason: The service battery has a connection problem. Recommendation: Check the connections of the service battery and its fuse.

SMARTPASS 120 FAULT INDICATIONS

	Reason: Service battery is overheating. Recommendation: Check the service battery with a battery tester and/or check the installation.
	Reason: Excessive current or internal temperature too high. Charging current too high to the service battery. Recommendation: Check the service battery with a battery tester. Reduce the alternator size or connect another D250SA in parallel. The service battery is too deeply discharged.
	Reason: Excessive current or internal temperature too high. Too many consumers connected simultaneously. Recommendation: Consider moving the apparatus to a cooler location or reduce the use of consumers.
	Reason: Excessive current or internal temperature too high. Current to the starter battery too high. Recommendation: Check the starter battery with a battery tester. Replace the starter battery if the warning repeats.
	Reason: Excessive current or internal temperature too high. Too many consumers connected. Recommendation: Consider moving the apparatus to a cooler location or reduce the use of consumers.
	Reason: Battery guard activated. Service battery not charged enough. Recommendation: Charge the service battery.
	Reason: Start assistance activated. Recommendation: Charge the starter battery. Replace the starter battery if the warning repeats.

TECHNICAL SPECIFICATION