Merlin PowerGuard PRO Fehlerbehebungshandbuch

PowerGuard PRO User & Installation Guide Rev A Page 1

PowerGuard PRO

Flat Battery Protection System

User & Installation Guide

Revision A

Merlin Equipment Ltd

Clyst Court

Hill Barton Industrial Estate

Exeter, Devon, EX5 1SA

United Kingdom

T: +44 (0) 1202 697979

Merlin Power Systems

332-4 West Montauk Highway

Hampton Bays

New York

NY11946

United States of America

T: +1(631) 594 5102

www.merlinequipment.com

PowerGuard PRO User & Installation Guide Rev A Page 2

WARNING

Your attention is drawn to “Caution!”and “Warning!”statements throughout this manual.

“Caution!”refers to practices that may cause damage to the PowerGuard PRO or your electrical

system.

“Warning!”identifies practices that may cause injury or death.

PowerGuard PRO is designed for installation by qualified and

competent electrical engineers.

Qualified and competent engineers will be familiar with safe working

practices, local health & safety legislation and the proper and safe use of tools

and equipment. Therefore not all obvious practices that may lead to system

damage, injury or death are detailed within this manual. If you are in anyway

unsure about any aspect of the installation or use of PowerGuard PRO, contact

your Dealer or Merlin Power Systems for advice.

PowerGuard PRO User & Installation Guide Rev A Page 3

Precautions

•This product is designed for use in 12Volt DC and 24Volt DC

vehicular systems depending on model. Use in other than its

designed application may result in fire, electric shock or other

injury.

•DO NOT disassemble, modify or alter. Doing so may result in an

accident, fire or electric shock.

•USE ONLY in vehicles with a NEGATIVE GROUND. Failure to do

so may result in fire, electric shock, damage or other injury.

•FUSES: Use the correct ampere rating when replacing fuses.

Failure to do so may result in fire, injury, electric shock or

damage.

•DO NOT install or operate the CPU in an explosive atmosphere.

•DO NOT install or expose the CPU to excessive temperatures or

humidity.

•If in any doubt consult a suitably qualified and competent

engineer or the supplier.

•DO NOT substitute Contactors or switches with any other types

that have not been approved and tested.

•MAINTENANCE. If you have problems or suspect device failures

DO NOT attempt to repair the unit yourself. Return it to your

Dealer or Merlin for servicing.

PowerGuard PRO User & Installation Guide Rev A Page 4

Certificate of Conformity

Declaration of Conformity

Merlin Equipment Limited, Trading as Merlin Power Systems hereby declares that the product

marketed as PowerGuard PRO is in compliance with the requirements of EU Electromagnetic

Compatibility (EMC) Directive 2014/30/EU.

PowerGuard PRO complies with RoHS (Reduction of Hazardous Substances) Directive 2011/65/EC.

At the end of life, PowerGuard Pro should be disposed of as normal electrical waste.

PowerGuard PRO has been tested to and surpasses ISO-7637-2 for use on vehicles.

Signed:

James Hortop

Managing Director

Merlin Power Systems UK

Date: 18th January 2019

VCA Approval Number: 10R-059235

Test report: TRA-025368-38-00A

PowerGuard PRO User & Installation Guide Rev A Page 5 
 
Introduction 
 
Thank you for purchasing a PowerGuard PRO. 
 
PowerGuard PRO is a remote battery switching system. This allows you to mount battery master 
switches in convenient locations such as dashboards or helm panels without needing to run heavy 
duty cables throughout the vehicle/boat. 
 
PowerGuard PRO is also a Flat Battery Protection System. Using sophisticated battery monitoring 
techniques, PowerGuard PRO detects when batteries start to run low. When the batteries have run 
below a certain level for a pre-set period of time, the battery will be disconnected. Note: on the 
primary battery circuit, this is inhibited from happening when the engine ignition is switched on. 
 
PowerGuard PRO may be used on 1 or 2 battery bank installations at either 12 or 24VDC. Those 
battery banks may also be of mixed voltage (e.g. a 12 and a 24V battery bank). 
 
Please take the time to read and understand this manual before installation and use. 
 
Please note that this manual refers to the PowerGuard PRO retail product. PowerGuard PRO is available 
in an OEM version. The OEM version differs slightly to the retail product. However, the main printed 
circuit board within PowerGuard PRO is identical so this manual may also be used for setting up the 
OEM version. 
 
Contents 
 
Precautions .............................................................................................................................................3 
Certificate of Conformity ........................................................................................................................4 
Introduction ............................................................................................................................................5 
Contents.................................................................................................................................................. 5 
Package Contents.................................................................................................................................... 6 
Installation .............................................................................................................................................. 7 
Positioning of Parts ............................................................................................................................. 7 
Wiring Layouts .................................................................................................................................... 8 
Contactor Rating ................................................................................................................................. 9 
Installation and Set Up.......................................................................................................................... 10 
Location and Connections.....................................................................................................................11 
Settings..................................................................................................................................................13 
Notes.................................................................................................................................................14 
After Installation - Testing ....................................................................................................................15 
Product Specifications...........................................................................................................................16 
Warranty ...............................................................................................................................................17 

PowerGuard PRO User & Installation Guide Rev A Page 6

Package Contents

Single Battery

Models: 04-8101(12V) and 04-8102(24V)

•PowerGuard PRO CPU x1

•PowerGuard PRO Contactor x1. Part Number: SU80-5164MPL(12V) or Part Number SU80-5165(24V)

•Remote Battery Isolator Switch x1

•Flat Battery Protection Reset Switch x1

•Fuse Kit & Rubber Blanking Plugs

•Installation Manual (this document)

Twin Battery

Models: 04-8103(12V) and 04-8104(24V)

•PowerGuard PRO CPU x1

•PowerGuard PRO Contactor x2. Part Numbers: SU80-5164MPL(12V) or Part Numbers SU80-5165(24V)

•Remote Battery Isolator Switch x2

•Flat Battery Protection Reset Switch x1

•Fuse Kit & Rubber Blanking Plugs

•Installation Manual (this document)

PowerGuard PRO CPU Contactor Switch

PowerGuard PRO User & Installation Guide Rev A Page 7

Installation

•Warning! Isolate power supply before starting installation.

Positioning of Parts

The following should be observed as parts of PowerGuardPRO are designed for wet/dirty environments,

but others are not.

Main CPU.

Caution! Damage will occur if the CPU is allowed to get wet.

Warning! Do not install the CPU in a petrol/gas engine room environment.

The CPU is designed for location in a dry environment (such as on cab side of engine room bulkhead

or a cupboard). It is suitable for installation in drier engine compartments on boats. However, it is not

sealed against moisture ingress. The CPU is NOT suitable for installation or operation in atmospheres

where there is a risk of ignition or explosion.

Contactors

These are designed to be installed under hood, in wet engine room environments and battery

compartments. The contactors are IP66 rated and will withstand hose downs. The contactor should

be located as close as possible to the associated battery.

Isolator & Reset Switches

Normally located on dash panels or alongside engine controls. They are IP66 rated from the front

and may be located in exterior positions.

PowerGuard PRO User & Installation Guide Rev A Page 8

Wiring Layouts

These wiring layouts cover the majority of installations.

Typical Single Battery System

Figure 1 Single battery wiring schematic

Typical Twin Battery System

Figure 2 Twin battery wiring schematic

PowerGuard PRO User & Installation Guide Rev A Page 9

CPU Wiring

Figure 3 PowerGuard PRO General Wiring Schematic

Caution! Ensure that the correct polarity is observed for CPU and Contactor wiring.

Failure to observe correct polarity of Contactor wiring will result in incorrect operation of the system

and may cause serious damage.

Serious damage to the PowerGuard PRO will occur if the wires to the Contactor coils are incorrectly

connected or short-circuited.

Contactor Rating

Contactors are rated for charging systems of up to 200A Continuously. They will also handle

intermittent cranking current of engines up to 725A.

PowerGuard PRO User & Installation Guide Rev A Page 10

Installation and Set Up

Operational Notes

PowerGuard PRO is a remote battery switching and flat battery protection system. This allows you to

mount battery master switches in convenient locations such as dashboards or helm panels without

needing to run heavy duty cables throughout the vehicle/boat.

PowerGuard PRO combines battery protection and remote switching. By monitoring the battery

voltage PowerGuard PRO can disconnect the battery (or batteries) from the loads to prevent excessive

and damaging discharge.

The Isolator switches provide a manual ‘override’ function to reconnect the battery (or batteries).

Remote Battery Switching

The Battery Isolator switches control connection or disconnection of the battery (or batteries).

PowerGuard PRO can switch up to 2 independent battery banks.

Flat Battery Protection

PowerGuard PRO can prevent a flat battery condition by disconnecting the battery (or batteries) from

the load. It achieves this by monitoring the battery voltage levels. If the voltage level falls below the

threshold for longer that the pre-set time, then the system is disconnected.

EMERGENCY OVERRIDE: Pressing the ‘override’ switch will re-connect the battery power.

The connect/disconnect voltage threshold level(s) and the pre-set time delay are set using the

trimming potentiometer (“trim-pots”).

In systems with 2 batteries (or 2 battery banks) the second battery is separately monitored and has a

separate contactor and Isolator switch to provide an ‘override’ function.

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