Issue 1 Print 4

C-CHARGER R
MARINE ELECTRONIC BATTERY CHARGER

LT9312405E1

INSTALLATION INSTRUCTIONS
& OWNERS MANUAL
40-, 50-, & 60-Amp 5000 Series

Marine Group

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

Page 1 of 14

LT9312405E1

Issue 1 Print 4

Contents
INTRODUCING... THE C-CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty/Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Environmental Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C-Charger Application Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Damaged C-Charger Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance/Cleaning Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal Safety Precautions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preparing to Charge Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting to the Battery Outside the Boat Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MISES EN GARDE IMPORTANTES (safety instructions in French) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLING THE C-CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Verifying Proper Battery/Charger Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Choosing Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Choosing Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting the C-Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting the Splash Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Choosing Electrical Wiring Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Choosing Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Making AC Connections on Terminal Block 1 (TB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Making DC Connections on Terminal Block 2 (TB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing External Fuse (not supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Closing the Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATING THE C-CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Changing Internal Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTAINING THE C-CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING THE C-CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WARRANTY & CUSTOMER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Warranty Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

LT9312405E1

INTRODUCING... THE C-CHARGER

Thank you for purchasing the C-CHARGER. Your C-Charger represents the latest in electronic, pulse-modulated
switching chargers. It is designed for hard-wired, on-board applications only, and converts AC shore power to DC
charging current to maintain a 12 volt marine battery. The 40-, 50- and 60-amp 5000 Series models charge up to
three battery banks simultaneously. All of the 5000 Series C-Charger units operate under a wide range of input
voltages yet maintain a constant output, avoiding any danger of overcharging marine batteries. The 5000 Series
units are equipped with a cooling fan and a temperature compensation circuit that automatically adjust to temperature variations, extending the life of batteries.
This manual covers the following models, listed by model number:
Table 1. 40-, 50- & 60-Amp 5000 Series C-Charger Model Numbers
Model
Number

Battery Type

Input
Voltage

Frequency

4 Hour
Float Rate
Bulk RaOutput
te Output
Voltage
Voltage

Ban
ks

Marine
UL Approved

Canadian
UL

12405E

LEAD ACID
(Wet/Flooded)

120VAC
*

60 Hz*

14.5
VDC

13.65
VDC

12405EG

GEL (Sealed Recombinant)

120VAC
*

60 Hz*

14.2
VDC

13.65
VDC

12405EI

LEAD ACID
(Wet/Flooded)

220VAC
**

50/60**

14.5
VDC

13.65
VDC

12405EIG

GEL (Sealed Recombinant)

220VAC
**

50/60**

14.2
VDC

13.65
VDC

12505E

LEAD ACID
(Wet/Flooded)

120VAC
*

60 Hz*

14.5
VDC

13.65
VDC

12505EG

GEL (Sealed Recombinant)

120VAC
*

60 Hz*

14.2
VDC

13.65
VDC

12505EI

LEAD ACID
(Wet/Flooded)

220VAC
**

50/60**

14.5
VDC

13.65
VDC

12505EIG

GEL (Sealed Recombinant)

220VAC
**

50/60**

14.2
VDC

13.65
VDC

12605E

LEAD ACID
(Wet/Flooded)

120VAC
*

60 Hz*

14.5
VDC

13.65
VDC

12605EG

GEL (Sealed Recombinant)

120VAC
*

60 Hz*

14.2
VDC

13.65
VDC

12605EI

LEAD ACID
(Wet/Flooded)

220VAC
**

50/60**

14.5
VDC

13.65
VDC

12605EIG

GEL (Sealed Recombinant)

220VAC
**

50/60**

14.2
VDC

13.65
VDC

* Will accept variances in input voltage from 90 to 135 VAC and variances in frequency from 45 to 65 Hz
with no degradation of output
** Will accept variances in input voltage from 180 to 270 VAC and variances in frequency from 45 to 65
Hz with no degradation of output
 Timer starts at 60% of rated output current
 At 25 C, output voltage is compensated at .04 VDC/C
Warranty/Registration
Before proceeding, complete and mail back the Warranty Registration card.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

LT9312405E1
Manual Purpose
With your personal safety in mind, this manual lists important safety precautions first, then covers installation,
operation, maintenance, troubleshooting and warranty and customer service information.
WARNING
RISK OF EXPLOSIVE GASES! WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. THEREFORE IT
IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CCHARGER YOU READ THIS
MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
To reduce risk of battery explosion, follow these instructions, those of the battery manufacturer, and
the manufacturer of any equipment you use in the vicinity of the battery. Review cautionary markings
on these products and on the engine.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions
for the C-Charger. Read the entire manual before usage. Also read all instructions and cautions for and on the
C-Charger and batteries.
Environmental Precaution
Do not expose the C-Charger to rain, snow, or excessive moisture.
C-Charger Application Precaution
These units are intended for hard-wired applications. Use of attachments not recommended or sold by Charles
Marine Products may result in risk of fire, electrical shock or personal injury.
Damaged C-Charger Precaution
Do not operate the C-Charger if it has received a sharp blow, been dropped, or otherwise damaged. See the section in this manual on Warranty & Customer Service.
Disassembly Precaution
Do not disassemble the C-Charger. See the sections in this manual on Maintaining the C-Charger, Troubleshooting the C-Charger and Warranty & Customer Service.
Maintenance/Cleaning Precaution
To reduce risk of electrical shock, disconnect the C-Charger from AC power and batteries before attempting any
maintenance or cleaning.
Personal Safety Precautions:
Adhere to the following personal safety precautions when installing or working with any of the 5000 Series CChargers:
1. Someone should be within voice range or close enough to come to your aid when you work near a
lead acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash them immediately with soap and water. If acid enters
the eye, flood the eye with cold, running water for at least ten minutes and get medical attention immediately.
5. Never smoke or allow a spark or flame in the vicinity of the battery or engine.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

LT9312405E1
6. Do not drop a metal tool onto the battery. It may spark or short circuit the battery or other electrical
parts that can cause an explosion.
7. Remove all personal metal items such as rings, bracelets, necklaces and watches when working near
a lead acid battery. A battery can produce short circuit currents high enough to weld a ring or the like
to metal, causing a severe burn.
8. The C-Charger is not intended to supply power to a low voltage electrical system other than in a marine application. Do not use the C-Charger for charging dry cell batteries that are commonly used with
home appliances. These batteries may burst and cause personal injury and property damage.
9. NEVER charge a frozen battery.
Preparing to Charge Precautions
CAUTION
To reduce risk of injury, charge only lead acid or gel cell type rechargeable batteries. Other types of
batteries may burst, causing personal injury and damage.
Before charging a battery with the C-Charger, read the following precautions:
1. Make sure all accessories in the boat are off.
2. If the battery must be removed from the boat, always remove the grounded terminal from the battery
first.
3. Be sure the area around the battery is well ventilated while the battery is being charged. Gas can be
forcefully blown away using a piece of cardboard or other non-metallic material as a hand fan.
4. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
5. Add distilled water in each cell until battery acid reaches levels specified by the battery manufacturer.
This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps, carefully
follow the manufacturers recharging instructions.
6. Study all battery manufacturers precautions, such as removing or not removing cell caps while
charging and recommended rates of charge.
Connecting to the Battery Outside the Boat Precaution
The 5000 Series C-Chargers have been specifically designed for hard-wired marine use inside a boat. They are
not designed or equipped for charging batteries on shore or outside a boat.
Grounding Precautions
When the C-Charger is permanently mounted inside the boat, it must have a grounding conductor.
1. The C-Charger should be connected to a metal, grounded, permanent wiring system. An equipmentgrounding conductor should be run with the circuit wiring and connected through the C-Charger housing grommets to the equipment grounding (GRN) terminal on the C-Charger.
2. Connections to the C-Charger should comply with all local codes and ordinances.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

LT9312405E1
French

MISE EN GARDE

Franais

DES GAZ EXPLOSIFS PEUVENT TRE PRSENTS. IL EST DANGEREUX DE TRAVAILLER PROXIMIT
DE BATTERIES AU PLOMB, QUI LIBRENT DES GAZ EXPLOSIFS DURANT LEUR UTILISATION
NORMALE. AINSI, IL EST TRS IMPORTANT QUE VOUS LISIEZ CE GUIDE CHAQUE FOIS QUE VOUS
UTILISEZ VOTRE CCHARGER, ET QUE VOUS EN SUIVIEZ SOIGNEUSEMENT LES INSTRUCTIONS.
Afin de rduire le risque d'explosion des batteries, suivez ces instructions, celles du fabricant de vos
batteries, et celles du fabricant de tout autre quipement utilis prs des batteries. Consultez les mises
en garde inscrites sur ces produits et sur le moteur.

MISES EN GARDE IMPORTANTES

CONSERVEZ CES INSTRUCTIONS. Ce guide contient dimportantes instructions sur la scurit et lutilisation du C-Charger. Lisez le guide en entier avant dutiliser le chargeur. Lisez galement les instructions
et mises en garde inscrites sur le C-Charger et celles relatives aux batteries.
Exposition du C-Charger aux intempries
Nexposez pas le C-Charger la pluie, la neige, ou lhumidit excessive.
Applications recommandes
Ces appareils sont conus pour les applications locales permanentes. Lutilisation daccessoires non recommands ni vendus par Charles Marine Products prsente des risques dincendie, de chocs lectriques ou de blessures.
C-Charger endommag
Nutilisez pas le C-Charger sil a reu un coup brusque, sil est tomb ou sil est endommag.
Dmontage
Ne dmontez pas le C-Charger.
Entretien et nettoyage
Afin de rduire le risque de chocs lectriques, dbranchez le C-Charger de la source de courant CA avant deffectuer tout entretien ou nettoyage.
Prcautions personnelles:
1. Demeurez porte de voix ou prs dune autre personne pouvant vous venir en aide lorsque vous
travaillez proximit dune batterie au plomb.
2. Prvoyez une bonne quantit deau frache et du savon en cas de contact des yeux, de la peau ou
des vtements avec lacide de la batterie.
3. Portez un quipement de protection complet pour les yeux et les vtements. vitez de toucher vos
yeux lorsque vous travaillez prs dune batterie.
4. Si lacide de la batterie entre en contact avec la peau ou les vtements, lavez-les immdiatement
avec de leau et du savon. En cas de contact oculaire, rincez aussitt les yeux leau courante pendant au moins dix minutes et consultez le mdecin immdiatement.
5. Ne fumez jamais et ne tolrez jamais les flammes ou les tincelles proximit de la batterie ou du
moteur.
6. vitez de laisser tomber des objets mtalliques sur la batterie. Cela peut produire une tincelle ou
provoquer un court-circuit dans la pile ou dans tout autre lment lectrique pouvant causer une explosion.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

LT9312405E1
7. Retirez tout objet personnel de mtal comme les bagues, bracelets, colliers et montres lorsque vous
travaillez prs dune batterie au plomb. Une batterie au plomb peut produire un court-circuit suffisamment fort pour faire fondre ces articles et provoquer des brlures graves.
8. Le C-Charger nest pas conu pour alimenter un systme lectrique de basse tension autre que celui
dune application marine. Nutilisez pas le C-Charger pour charger les batteries anode sche employes dans les appareils mnagers. Ces batteries peuvent exploser et causer des blessures et des
dommages.
9. NE CHARGEZ JAMAIS une batterie gele.
Prparation du chargeur
French

ATTENTION

Franais

Afin de rduire les risques de blessures, ne chargez que des batteries rechargeables au plomb. Les
autres types de batteries peuvent exploser et causer des blessures et des dommages.
1. Si la batterie doit tre dabord retire de lembarcation, dbranchez toujours la mise la terre de la
batterie en premier lieu. teignez tous les accessoires de lembarcation, afin dviter de produire un
arc lectrique.
2. Assurez-vous que lendroit o se trouve la batterie soit bien ar lorsque la batterie est charge. Les
gaz peuvent tre loigns laide dun ventail fait de carton ou de tout autre matriau non-mtallique.
3. Nettoyez les bornes de la batterie. vitez le contact de la corrosion avec les yeux.
4. Ajoutez de leau distille dans chaque cellule jusqu ce que lacide atteigne le niveau spcifi par le
fabricant. Ceci contribue liminer les excs de gaz dans les cellules. Najoutez pas trop de liquide.
Si les cellules ne possdent pas de couvercle, suivez les instructions du fabricant pour charger la
batterie.
5. tudiez toutes les mises en garde du fabricant de la batterie. Par exemple, vrifiez sil faut retirer les
couvercles des cellules pendant la charge, et prenez connaissance des taux de charge recommands.
Branchement de la batterie lextrieur de lembarcation
Les C-Charger de la srie 5000 ont t spcialement conus pour les applications marines permanentes bord
dune embarcation. Ils ne sont pas conus pour charger les batteries au quai ou lextrieur de lembarcation.
Mise la terre
1. Votre C-Charger doit tre reli une canalisation lectrique mise la terre, mtallique et permanente. Un conducteur de protection doit tre reli au circuit de branchement, et branch la borne de
mise la terre (GRN) du C-Charger, laide des passe-fils.
2. Les connections au C-Charger doivent tre conformes tous les codes et ordonnances locaux.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

LT9312405E1

INSTALLING THE C-CHARGER

Verifying Proper Battery/Charger Type
C-Charger models may be used for charging LEAD ACID (wet/flooded) or GEL CELL (sealed recombinant) batteries. Confirm the intended battery type with the model number on the product identification label located on the
C-Charger (refer to Table 1). All C-Chargers have been factory preset. If your C-Charger model does not match
your intended battery type, contact Charles Marine Customer Service at 847/806-6300 for further assistance.
Choosing Mounting Location
The C-Charger should be mounted vertically flush on a bulkhead in a protected area away from rain or spray and
as close to the batteries as possible. The C-Charger is designed to operate in high ambient temperatures, with
the proper ventilation. Six inches of unobstructed area on all sides of the unit should be allowed for air circulation
and cooling.
Note:

The 40-, 50- and 60-amp C-Chargers are equipped with a cooling fan. The fan will start operation when
the load is approximately 50% of the maximum rated output current. Also, a temperature compensation
circuit exists to automatically adjust to room temperature variations. A temperature coefficient of
0.04VDC/C causes the output voltage of the C-Charger to change inversely with the change in room
temperature. The purpose of this circuit is to extend the life of the batteries.

Choosing Mounting Hardware

As with any marine equipment, secure mounting is of utmost importance. The bolts or screws used to secure the
C-Charger must be 1/4 inch in diameter, backed with a flat washer, and kept vibration-free with a split-ring lock
washer. If using bolts, they must be long enough to be secured on both sides of the bulkhead. If using screws,
they should be at least 1 inch long. All hardware should be corrosion-resistant.
Mounting the C-Charger
All corrosion-resistant mounting hardware should be readily available. Follow the steps below to mount the CCharger to the bulkhead.
Action

Step
1.

Hold the C-Charger vertically flush on the bulkhead

2.

Mark the mounting holes

3.

Remove the C-Charger

4.

Drill the mounting holes

5.

Insert one side of the mounting hardware half-way into the drilled mounting holes

6.

Align the mounting slots on the C-Charger with the secured hardware and slide the C-Chargers mounting flange under the washers

7.

Insert the mounting hardware for the other side

8.

Secure all mounting hardware.

Mounting the Splash Guard

Position and install the splash guard (Figure 1) over the C-Charger so that the back flange bottom rests on top of
the C-Charger. This insures proper vertical spacing for ventilation. For optimum splash protection, be sure to center the splash guard horizontally over the C-Charger. Secure with 1/4-inch diameter screws, approximately 1/2
inch long.
Choosing Electrical Wiring Hardware
The C-Charger is intended for hard-wiring in a permanent application. Conduit or other appropriate marine electrical installation hardware should be used.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

LT9312405E1
Choosing Wire Gauge
Use Table 2 and Table 3 to determine the appropriate wire gauges. Avoid unnecessarily long runs of either AC or
DC power lines.
DANGER
Before working on electrical equipment, first determine there is no live power! Double check power
connections and all battery terminations.

French
Franais
DANGER
Avant de manipuler les quipements lectriques, veillez ce que le courant soit interrompu. Vrifiez
soigneusement les branchements la source de courant et aux bornes de la batterie.

Table 2. Minimum Wire Size to Input of CCharger

120 VAC SHORE POWER INPUT TO C-CHARGER
Model Number

AC Amp Max

25 Length

50 Length

100 Length

12405E, 12405EG

10

16 AWG

14 AWG

10 AWG

12505E, 12505EG

12

16 AWG

12 AWG

10 AWG

12605E, 12605EG

13

14 AWG

12 AWG

10 AWG

220 VAC SHORE POWER INPUT TO C-CHARGER

12405EI, 12405EIG

18 AWG

16 AWG

14 AWG

12505EI, 12505EIG

18 AWG

16 AWG

12 AWG

12605EI, 12605EIG

16 AWG

14 AWG

12 AWG

Table 3. Minimum Wire Size from Output of CCharger to Battery

C-CHARGER DC OUTPUT TO BATTERY
Model Number

DC Amp Max

15 Length

25 Length

12405E, 12405EG, 12405EI, 12405EIG

40

8 AWG

6 AWG

12505E, 12505EG, 12505EI, 12505EIG

50

6 AWG

6 AWG

12605E, 12605EG, 12605EI, 12605EIG

60

6 AWG

6 AWG

WARNING
External connections to the CCharger shall comply with the U.S. Coast Guard Electrical Regulations
(33CFR183 subpart I).
Franais
MISE EN GARDE
Les branchements externes du CCharger doivent tre conformes aux rglementations de la garde
ctire amricaine en matire d'lectricit (no 33CFR183 section I).
French

Making AC Connections on Terminal Block 1 (TB1)

After determining the wire lengths and gauges, make the AC wiring connections to TB1. (Refer to the Block Diagram in Figure 1.) Use spade terminals, and torque the screws to 8 +/1 inch/pounds. To make connections to
the terminal blocks:

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LT9312405E1
Step

Action

1.

Remove the small screw in the center of the unit that secures the sliding door to the top cover

2.

Gently slide the door up until it stops

3.

Bring the AC input wire in through the left side access hole on the bottom of the C-Charger

4.

Connect the WHT terminal to the white (neutral) input

5.

Connect the BLK terminal to the black (hot) AC input

6.

Connect the GRN terminal to the green (ground) input.

DANGER
Do not operate this unit without the green wire connected to the CCharger and to suitable ground at
shore connection.
French

Franais

DANGER

N'utilisez pas cet appareil si le fil vert n'est pas branch au CCharger et une mise la terre adquate
au quai.
Note:

Read this manual and all precautions before installing or making connections!

F2

F1
WHT BLK GRN

TB1

Note 1

+DC

To AC
ground bus
(green)

To AC hot (black)

TB2

+DC

DC
Fuses
(see Table 4
& Note 5

Splash Guard

PCB
(1240 EL shown)

-DC

Negative (black)

Note 2

Positive
(red)
Positive (red)

AC power
source
circuit
breaker
(min. size
15 amps

+DC

30A/32V FAST ACTING

F3

12A/250V
SLO-BLO

AC
Fuse
(see Table 4
& Note 5)

Note 3

Note 3

+
Battery 1

Positive (red)
Note 4
+
Battery 3

+
Battery 2

To AC neutral bus (white)

Notes
1. AC stranded wire (see Table 2).
2. DC stranded wire (see Table 3).
3. External fuse/circuit breaker installed within 72 of C-Charger. (See Coast Guard Reg. 33CFR183 subpart I.)

Access to
PCB TB1 &
TB2 terminals & F1, F2
& F3 fuses

4. Black jumper (common negative) - minimum 8 AWG (only necessary if batteries are not pre-wired with common negative).
5. Internal fuse size is for 40-amp model. See Table 4 for 50- and 60-amp model fuse sizes.

Figure 1. 40-, 50- and 60-Amp 5000 Series Block Diagram

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LT9312405E1
Making DC Connections on Terminal Block 2 (TB2)
After the appropriate wire lengths and gauges have been determined, make the DC connections to TB2. (Route
the DC wire through the right-side access hole on the bottom of the C-Charger.) TB2 has three positive (+) terminals for up to three battery banks. One negative () terminal is provided that is common for all battery banks.
WARNING
In accordance with ABYC E9, a fuse or circuit breaker must be placed within 72inches of the point of
connection to the batteries or its buss on all positive output conductors. Also see Coast Guard Reg.
33CFR183 subpart I.
Franais
MISE EN GARDE
Selon la norme amricaine ABYC E-9, un fusible ou un disjoncteur doit tre plac moins de 1,8 m
(72 po) du point de branchement des batteries ou de ses bus sur tous les conducteurs de sortie
positifs. Consultez les rglementations de la garde ctire amricaine (no 33CFR183 section I).
French

Installing External Fuse (not supplied)

A fuse or circuit breaker (not provided) must be installed within 72-inches of the C-Charger on each positive (+)
DC output wire that is connected to a battery bank. Use a 60-amp fuse for 40-amp models and an 80-amp fuse
for 50- and 60-amp models. See Figure 1 Note 3 for the location of this external fuse or circuit breaker.
Note:

The C-Charger comes equipped with three internal fuses: F1, F2 and F3. F1 is either a 12A slow-blow
input fuse for the 40-amp model or a 15A slow-blow input fuse for the 50- and 60-amp models. F2 and F3
are 30A fast-acting output fuses for the 40-amp model or 40A fast-acting output fuse for the 50- and
60-amp models.

Closing the Access Door

Before closing the access door, make sure that all electrical connections have been properly made at all the battery banks (most important) and at the C-Charger. Also check that all wiring is properly dressed with no exposed,
bare wires. Pull down the C-Charger access door and secure it to the top cover with the small screw provided.
Applying Power
Apply shore power to the unit and turn on the AC power source circuit breaker. Check the front-panel ammeter for
movement. A substantial movement in a clockwise direction indicates the batteries need a charge (there should
be a slight movement even if the batteries are charged). If a counter-clockwise movement occurs, turn off power
immediately and refer to Table 5.
If the C-Charger does not charge batteries or perform as described, refer to the section in this manual on Troubleshooting the C-Charger.

OPERATING THE C-CHARGER

Always follow all precautions in the IMPORTANT SAFETY INSTRUCTIONS section in this manual.
Proper Operation
When properly installed and connected, the C-Charger will automatically charge and maintain the batteries. When
power is applied, the C-Charger will enter a bulk or constant current mode, during which a higher rate of charge
is achieved to fully replenish the batteries. When the batteries near a full charge, the output current will decrease
and the charger will enter a timed absorption mode. After four hours in absorption mode, the output will drop to a
float rate to maintain the batteries at a temperature compensated finishing voltage (13.65 VDC @ 25C for lead
acid).
Changing Internal Fuses
Irregular conditions or loads may cause one or more of the internal fuses to blow. ALWAYS determine there is no
live power before replacing a fuse. To access the fuses, remove the small screw in the center of the unit that secures the sliding door to the top cover. Slide the access door up until it stops. The AC fuse (F1) is located just
above the AC terminal block (TB1) and the DC fuse (F2) is located above the DC terminal block (TB2). When
replacing fuses, use only fuses of the exact type and rating (See Table 4). Before reapplying power, pull down the
access door to close it. Once down, secure the access door to the top cover with the small screw provided.

Charles Industries, Ltd. All rights reserved. Printed in the United States of America.

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LT9312405E1
Table 4. Internal Fuse Replacement Sizes
Model Number

AC Input (F1)

DC Output (F2)

12405E, 12405EG, 12405EI, 12405EIG

12-Amp/250 Volt SLO-BLO 30-Amp/32 Volt FAST ACTING

12505E, 12505EG, 12505EI, 12505EIG,

12605E, 12605EG, 12605EI, 12605EIG

15-Amp/250 Volt SLO-BLO 40-Amp/32 Volt FAST ACTING

MAINTAINING THE C-CHARGER

There are no adjustment or maintenance requirements for the C-Charger other than cleaning the outside cabinet
with a dry cloth. Periodically have all connections checked by a qualified service person, especially if the boat is
operated in heavy, pounding seas.
CAUTION
Check battery water levels frequently, especially if the boat is at dock for extended periods of time.
Low water levels will damage batteries!
Franais
ATTENTION
Vrifiez frquemment le niveau des liquides de la batterie, surtout si l'embarcation demeure quai
pendant de longues priodes. Des niveaux trop bas peuvent endommager les batteries.
French

TROUBLESHOOTING THE C-CHARGER

If there is a problem with the C-Charger, first check all connections and retest. If all connections are good, see if
the problem is covered in Table 5. If the problem is not covered in Table 5, or if the C-Charger still malfunctions
after performing the solution given, contact Charles Marine Products for technical assistance.
Table 5. Troubleshooting Suggestions
Condition

Solution

Not clear if batteries

are fully charged.

As the batteries charge, the ammeter gradually falls. When it reads zero, the batteries
are fully charged.

It takes too long to

charge batteries.

The C-Charger brings a discharged battery voltage level up slowly to avoid shortening
the life of the battery. The recharge time depends on the degree of discharge.

Unable to identify if
lack of battery charge
is due to a battery
problem or a C-Charger problem.

When the ammeter reads zero, test the condition of a battery by first turning off the AC
power source to the C-Charger, and disconnecting the battery from the C-Charger for
at least one hour. Connect battery to an ohm-volt meter. A reading of 12.6 VDC or
more is desirable. A reading between 12.4 and 12.6 indicates a charge between 75 and
100%. A reading between 12.2 and 12.4 VDC indicates a charge between 50 and 75%.
Consult the battery manufacturers Owners Manual for instructions.
If it appears the battery is operating properly, proceed to check the following only after
reading and fully understanding all safety instructions listed in this manual. Check input
voltage at 120 VAC, check the C-Chargers AC fuse and DC fuse, check the battery
fuse/AC circuit breaker (Figure 1, Note 3) and check all associated wiring connections.
If these appear to be working, the C-Chargers DC output can be tested by turning off
all AC power to the unit and then disconnecting all DC outputs from the charger. Upon
reapplying AC power, the DC voltage between any (+) and () output terminal on TB2
should be between 13.5 and 15 volts DC. Should the unit still be inoperable after all
tests have been completed in sequence, refer to the section in this manual on Warranty
& Customer Service.

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LT9312405E1
Condition

Solution

The ammeter deflects Disconnect the unit immediately. Examine wiring instructions again to assure proper conin a counter-clockwise nections. A movement in a counter-clockwise direction or a full-scale movement indicates
direction.
excessive current. A wiring error is suspected. A voltmeter can monitor the voltage at the
battery when the C-Charger is turned on. An increase in voltage should occur as power
is applied.
Internal red LED on.

The unit is at half-power because the ambient air is too hot. The unit may be at halfpower because the fan is not working. Full power will be restored when the temperature
returns to normal.

WARRANTY & CUSTOMER SERVICE

Warranty
CHARLES MARINE PRODUCTS warrants the 5000 Series C-Charger will be free from defects in materials and
workmanship which cause mechanical failure for five (5) years, as set forth in the Limited Warranty. Review this
warranty carefully for information on what is covered by its terms. Complete and return the warranty registration
card within ten (10) days of purchase to establish proof of ownership and validate the warranty coverage. You
must provide notice of any alleged defect in material or workmanship within thirty (30) days of discovering the
problem, and within the warranty period. Follow the procedure outlined below to obtain warranty service.
Warranty Service and Repair
If the unit fails to operate properly after following all the instructions in the manual, or if the C-Charger requires
service, take the following steps:
1. Contact Charles Marine Products Customer Service and obtain a Returned Goods Authorization
(RGA) number and a Service Center address
2. Ship or mail the C-Charger together with the RGA to the appropriate Service Center. Shipping costs
to and from the Service Center are your responsibility
3. When service is complete, Charles Marine Products will return the C-Charger to you.
Customer Service
If technical assistance or customer service is needed, contact Charles Marine Products at:
847/806-6300 (Customer Service)
847/806-6231 (FAX)
905/821-7673 (Canada)
For correspondence only, mail to:
Charles Marine Products
Charles Center
5600 Apollo Drive
Rolling Meadows, IL 60008-4049

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LT9312405E1

SPECIFICATIONS
The specifications for the 40-, 50- & 60-amp 5000 Series C-Chargers are listed in Table 6.
Table 6. 40-, 50- & 60-Amp 5000 Series C-Charger Specifications
40-Amp Model

Feature

50- & 60-Amp Models

Weight

9 lb. (4.1 kg)

10 lb. (4.5 kg)

Height

13.25 in. (33.7 cm)

15.25 (38.7 cm)

Width

9.5 in. (24.1 cm)

9.5 in. (24.1 cm)

Depth

3.7 in. (9.4 cm)

3.7 in. (9.4 cm)

AC Input*

120 VAC nom

220 VAC nom

120 VAC nom

220 VAC nom

*See the label on the side of the charger for the operating voltage.

  

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