DCtoGO Battery Box w/ RIGrunner 4008 and Super PWRgate PG40S

Product Overview

The DCtoGO provides convenient portable power. The case accepts Group Size 24 batteries, providing up to 100 amp hours at 12 volts. Eight devices may be plugged into the integrated RIGrunner 4008 power strip. Each socket is fused for protection. Any blown fuse will be illuminated. Correct and low voltage indicators show battery status. The battery may be charged via the power strip.

Contents

• Battery Box with strap
• RIGrunner 4008 (mounted directly to battery box)
• Power Supply Cable (2ft. #10 wire, ring terminals to Powerpoles)
• 12 pair pak of 30A Powerpole connectors and contacts
• DCtoGO Operating Manual

Safety Information

A battery stores a large quantity of energy. A short circuit will release this energy rapidly causing the wire to melt, and perhaps, catch on fire. Also, the battery could explode. The fuse located near the battery terminal in the RIGrunner may help prevent these types of catastrophes.

Batteries

The use of only SAFETY batteries is recommended, such as gelled-electrolyte and absorbed-glass mat (AGM) types. These batteries are sealed and contain no dangerous gases. These types may be mounted in any position, although vertical is preferred. They are also 100% maintenance free.

Use of other types of batteries for portable use in the DCtoGO is NOT recommended. Automobile batteries and marine batteries may only be used if the installation is fixed; where the battery box will not be turned over and is located outdoors or in a well-ventilated area.

West Mountain Radio carries high-quality gelled-electrolyte and AGM batteries. They have posts and lugs with studs to match the ring terminals on the supply cable provided.

DCtoGO Battery Box Dimensions

Connecting to the Battery

Connect the ? RED wire with the larger ring terminal to the battery POSITIVE (+) lug and securely fasten with the nut. Connect the ⚫ BLACK wire with the smaller ring terminal to the battery NEGATIVE (-) lug and securely fasten with the nut. Ensure that RED is POSITIVE and BLACK is NEGATIVE.

Bring the wire out through the front of the battery box to the left of the RIGrunner. Plug into the farthest left connector marked "DCIN". Neatly fold the excess wire into the box. Make sure the top is oriented so that the large vent is facing the front. Snap the top into place.

West Mountain Radio carries post-to-stud lug sets. The positive lug matches the larger size battery post and has a 3/8 inch stud. The negative lug matches the smaller size battery post and has a 5/16 inch stud.

Using the Strap

The strap may be installed and used to secure the battery box to the floor and to restrain the top cover. It also provides a safety precaution: in the event the battery explodes, the plastic box with strap will likely prevent flying debris and acid.

The strap is easily installed between the RIGrunner and the battery box.

RIGrunner 4008 Considerations

There are some considerations to think about. Please read these instructions carefully before setting up your RIGrunner.

Choosing a Mounting Location

Pick a location that is close or central to most of your radios and accessories, especially those that draw large amounts of current. Locate your power source as close as possible to the RIGrunner. Remember that every wire has resistance; longer wires have more resistance. More than a 10' run of #10 wire is not adequate to supply the RIGrunner to full output without a significant voltage drop.

Install in a cool dry place with good ventilation. Do not place it on top of an amplifier or room heater, or cover it. Avoid placing it in the engine compartment of a car, or directly on the floor of a car, as rain from open windows or snow-covered boots may cause water damage.

Connecting Your Equipment

Updating your cables to use 12 volts DC with Powerpoles will improve the convenience of quick connections. Powerpoles are genderless, and the same connector arrangement works for both supply and load. Powerpoles can be used to charge or power batteries.

Powerpoles can be installed by soldering or crimping. Ensure good connections. For detailed Powerpole connector installation tips, see RIGrunner support pages at www.westmountainradio.com/supportrr.

❗ IMPORTANT: It is essential that assembly of the pairs is correct. Follow the amateur radio standard used by the RIGrunner. DO NOT PLUG IN without verifying that RED + PLUS and BLACK – MINUS is correct.

The far left connector is labeled DCIN with a 40 amp fuse and is normally used to connect to the power supply. Any output may be used as the input with an appropriate fuse. Plug in your equipment starting with the highest power connections to the left and lower power drain units to the right. Note the supplied fuse ratings next to the connector chosen. Typically, 12 volt input amplifiers and 100 watt RF output transceivers should be first, VHF radios next, and smaller accessories last.

Multiple amplifiers and/or transceivers may be connected to the RIGrunner. The total allowable current is 40 amps. Most radios and amplifiers draw less than 3 amps in receive but require many more amps in transmit. The limiting factor is total current draw while transmitting. Consult the radio manual for power consumption specifications to determine how many radios may be used to transmit at one time. If the total current exceeds the 40 amp maximum, a fuse will blow, or an undersized power supply may be overloaded. The RIGrunner and any equipment plugged into it should remain unharmed.

Using the Proper Fuses

The RIGrunner comes supplied with a range of fuses. Every RIGrunner output is safe up to 40 amps, but the total allowable is also 40 amps.

A fuse MUST be in each position in use. ANY ATTEMPT TO BYPASS OR SHORT ACROSS THE FUSES IS DANGEROUS AND VOIDS THE RIGRUNNER WARRANTY. Standard ATC/ATO automotive blade fuses are used, available in 10 values from 1 amp to 40 amps.

The DC input should have a fuse appropriate for the power supply rating. If using a smaller power supply, consider a lower value fuse than the supplied 40 amp. Ideally, all outlets should have a fuse that is the next higher value above the maximum current draw of the unit on that fuse. If using a power cord with a fuse, match that value or go one or two values higher. Sizing each fuse for each unit is desirable but not necessary. A higher value offers less protection; too low a value will cause the fuse to blow prematurely.

Each fuse position has a LED blown fuse indicator that lights up if an output fuse is blown. There must be power to the RIGrunner and a load on the circuit with the blown fuse for the LED to light.

The Voltage Comparator and Audible Alert

The RIGrunner 4012 and 4008 feature a precision expanded scale voltage comparator display with an audible alert. (Models 4005 and 4004U do not have this feature.) A basic explanation of 12-volt systems is helpful. Equipment referred to as 12-volt is actually nominal 13.8 volts. A lead-acid battery is nominal 12.6 volts when charged and not under load, and approximately 14.0 volts under charge. A quality 12-volt power supply has a regulated output set to 13.8 volts. Most radios require 13.8 volts +/- 15%. Automobile or aircraft alternators have voltage regulation between 13.5 and 14.3 volts.

The RIGrunner provides an accurate voltage display with three LEDs: ? red (overvoltage), ? green (normal), and ? yellow (undervoltage). The change points are set to 11.5 and 15.0 volts.

• ? Yellow LED (Undervoltage): Less than 11.5 volts. This should be safe for your radio but may cause improper operation. Low voltage can cause loss of phase lock and frequency error. It indicates a problem with the power source (bad connection, unregulated supply, bad alternator, dying battery). It is normal for cars to have less than 11.5 volts when cranking the starter motor.
• ? Green LED (Normal): Between 11.5 and 15.0 volts. Everything is good.
• ? Red LED (Overvoltage): Warning! DISCONNECT OR TURN OFF YOUR POWER SUPPLY IMMEDIATELY! Overvoltage can overheat or damage equipment. An audible alert will sound.

When running on a 12-volt battery, overvoltage will not occur. The RIGrunner's audible alert can be reconfigured for a low battery warning by moving the P14 jumper to the "LO" position (requires removing four cover screws). Remember to move it back to "HI" when changing back operation from power supply or alternator.

? Note: It is normal for the undervoltage LED to glow dimly with a normal or overvoltage indication. It is also normal for LEDs to change intensity through precision points.

In the event of a bad power source or connection, the yellow LED may flash or come on during transmit. Check the power source and connections. RF from a transmitter can cause an electronically regulated power supply to lose regulation, triggering an overvoltage alert. The RIGrunner is RF bypassed to mitigate this. If overvoltage occurs during transmit, especially with a VHF high power amp, it may be due to inadequate RF filtering on the amplifier's DC lead or poor RF immunity of the power supply regulator.

RIGrunner Accessories

To purchase or view other accessories available, call or go online at: www.westmountainradio.com/shop

Introduction to Super PWRgate PG40S

The Super PWRgate PG40S is a high power OR Gate with a built-in four-stage battery charger, providing a true solid-state UPS for the ham shack.

The Super PWRgate PG40S eliminates the danger of connecting a power supply directly across a battery, which can damage power supplies. The PG40S also avoids introducing hum and RF interference common to most lead-acid battery chargers by using a standard power supply. Furthermore, most lead-acid battery chargers are designed for flooded lead-acid marine or automotive batteries and are inappropriate for charging sealed lead-acid gel and AGM type batteries. The PG40S extends the lifespan of a sealed lead-acid battery compared to using a flooded lead-acid charger.

Super PWRgate PG40S Operation

The PG40S transfers 40 amperes at 12 volts DC continuously and safely. It connects a battery and a power supply to a load, electrically isolating both from each other. When the power supply is on, it feeds the load and charges the battery with a high-current four-state charger. When the power supply is off, the battery feeds the load. If either the power supply or battery malfunctions, neither draws current from the other. The switching is instantaneous.

The PG40S is useful in the ham shack and even more so in repeater installations. Communication equipment remains operative during AC power blackouts and power supply failures. Power supplies and batteries can be swapped out while equipment continues to be powered without glitches.

Additionally, the PG40S and a power supply can be used solely as a permanently installed battery charger. This configuration can also run a radio station directly from the battery. (See the article by W1ZR in QST, December 2003 at www.westmountainradio.com/...)

Please read the following instructions BEFORE installing the PG40S

Choosing a Mounting Location

Pick a location close or central to the power supply, battery, and the load or 12V distribution panel. Radios and many 12V devices draw large amounts of current. All wires have resistance, so keep them as short as possible and use a larger gauge wire to minimize voltage drop.

The PG40S can be installed in any orientation. Use in a cool, dry, and preferably well-ventilated location. Do not tightly enclose the unit, as the heat sink can become warm under maximum current. At 40A continuous current, it will rise about 40 degrees Fahrenheit over ambient temperature in free air. Placing it in direct sunlight will cause it to absorb heat and become unnecessarily hot.

The Super PWRgate can be mounted using #8 hardware in the two mounting holes.

Connecting the Power Supply

Use a regulated power supply between 13.8 volts and 15 volts. Anderson Powerpoles are used for all Super PWRgate connections. See the section "Powerpole connector installation tips".

The power supply wire should be heavy gauge and as short as possible; recommend #10 wire, 3 to 6 feet long. Most power supplies have 1/4 inch studs. West Mountain Radio carries 3 and 6-foot power supply cables, #10 red and black insulated wire, with 1½" ring terminals on one end and Powerpoles on the other.

Connect the ? RED Powerpole to the RED wire and the PLUS (+) terminal on the supply. Connect the ⚫ BLACK Powerpole to the BLACK wire and the NEGATIVE (-) terminal on the supply. Ensure connections at the power supply are tight.

Plug this cable from the power supply into the Super PWRgate connector marked PS (power supply). Confirm that the Powerpoles are plugged together securely and the wire is straight at the connection point, not under strain or bent.

Connecting the Load or Power Strip

Anderson Powerpoles are used for all Super PWRgate connections. See the section "Powerpole connector installation tips".

The load wire should be heavy gauge and as short as possible. If connecting directly to a radio or other device, you will need to install Powerpoles on those cords. Modern radios use RED wire for positive and BLACK wire for negative (or common or ground). Refer to the equipment manual if you have non-standard equipment. Plug this wire into the Super PWRgate terminal marked OUT.

If connecting the output to a power strip, such as a RIGrunner, use #10 wire, 3 to 6 feet long. At least one end needs Powerpoles installed; the other end can wire directly to the power strip or use connectors. West Mountain Radio carries 3-foot and 6-foot extension cables, #10 red and black insulated wire, with Powerpoles on both ends.

Plug this wire from the power strip or equipment into the Super PWRgate connector marked OUT (output). Confirm that the Powerpoles are plugged together securely and the wire is straight at the connection, not under strain or bent.

At this point, check system operation with the power supply. Turn on the power supply and the radio or equipment. The radio or equipment should work properly.

Connecting the Battery

Anderson Powerpoles are used for all Super PWRgate connections. See the section "Powerpole connector installation tips".

The battery wire should be heavy gauge and as short as possible; recommend #10 wire, 3 feet long. A fuse must be installed in the positive lead directly at the battery terminal. Note: any short in the battery wire, connector, or load could result in fire and battery explosion.

Batteries (Detailed)

Large batteries have side, post, or threaded terminals. Deep cycle, marine, AGM, and others usually have 3/8 inch and 5/16 inch studs. It is recommended to use a short 3-foot #10 wire, Powerpoles on one end, an in-line fuse (40 A max), and ring terminals for the battery end. West Mountain Radio carries a battery fuse kit, wire, and Powerpoles.

Caution: Handle batteries with knowledge and appropriate care. Batteries contain dangerous chemicals that can seep out and emit extremely explosive hydrogen gas. Batteries, especially automotive and marine flooded lead acid, must be used in a strong, ventilated enclosure. Sealed lead acid batteries are safer but must be handled with care.

NEVER make the last connection directly to a battery, as a spark could cause the battery to explode, sending debris and acid in all directions. Batteries can get very hot when improperly charged or if a cell gets shorted. Batteries can explode during charging or discharging for various reasons; they are safe when handled properly.

Choose a 12-volt battery with an ampere-hour rating according to your power needs. If batteries are placed indoors, they must be sealed for safety. It is very important to place a fuse at the positive battery terminal.

This manual does not cover all battery types, but for ham shack use, lead-acid types are recommended for their price-to-power ratio. Gelled cells and absorbed glass mat (AGM) batteries are sealed and safe. Some have a tiny positive pressure vent. Gelled cells are best with the Super PWRgate as its charging circuit is configured to match a 13.8-volt power supply. If using AGM batteries, it is suggested to slightly elevate the power supply voltage and add a jumper change inside the Super PWRgate. Other types like "starting", "deep cycle", "marine", or automobile batteries are not recommended.

For additional battery information, visit: www.windsun.com/batteries/battery_FAQ.htm

West Mountain Radio carries size 24 Gelled and AGM batteries.

System Checkout

When the power supply and battery are connected, and the Super PWRgate is driving a radio, follow this checkout procedure:

• Run your radio, then unplug the power supply. The radio should operate without interruption from the battery.
• Plug the power supply back in; the radio will now be powered from the supply. An ammeter on the supply will show current.

It is recommended to use an in-line meter, such as the Power Analyzer sold by West Mountain Radio, which measures volts, amperes, watts, ampere-hours, and watt-hours simultaneously.

Place the Power Analyzer in-line with the power supply to measure its output. Unplug the load from the Super PWRgate to measure the battery's charging current. Plug the Power Analyzer into the Super PWRgate's output to measure either the power supply current (if connected) or the battery's output current (if the supply is disconnected or off).

Refer to the charging circuit description to verify different states when measuring charging current.

Voltages

Manufacturers list the lowest recommended DC supply voltage range for specific radio models. Some radios are listed as 13.8 VDC +/- 15%, others as 13.8 VDC +/- 10%.

12-volt power supplies are regulated to provide 13.8 volts DC. The Super PWRgate has a diode in series with a voltage drop of 0.25 V for 50 mA to 0.50 V at 40 amperes. Under normal load, the Super PWRgate output will be no less than 13.5 volts.

Fully charged 12-volt batteries exhibit around 13.5 volts open circuit. When supplying current, the battery's internal resistance diminishes the voltage. For instance, a 70 A-h battery will drop to 12.3 volts at 10 amperes at half discharge. The Super PWRgate will give a drop of 0.3 volts at 1 ampere, providing 12.0 volts to the radio.

Additional voltage drops can occur due to high current and resistance in wires, fuses, and connectors. Keep all wires as short as possible, use low gauge wire, and minimize connectors. Use a large fuse (30 or 40 amp) on the battery to keep its voltage drop low. Use a voltmeter to check the voltage at the radio when running on battery power.

Super PWRgate Charger

The charging circuit is a four-state high-current battery charger. It uses the power supply as the current source and charges the battery automatically based on its voltage. It also changes state if the power supply goes from "off" to "on" after an outage, or if the battery voltage drops when supplying heavy current. These conditions provide automatic charging.

The charger is safe and supplies rated current for heavily discharged batteries. Current drops smoothly as the battery nears full charge. The charger is a feedback device and cannot overcharge a 12-volt battery or charge a battery with a dead cell.

The charging circuit has four selectable charging current settings: 1A, 4A, 7A, and 10A, chosen appropriately for the battery's rating.

Charging States

• Trickle Charge: If the battery is below 10 volts, a low current of 50 mA is supplied. This is safe for a dead cell. If the battery is good, voltage will slowly rise above 10 volts, and the charger will switch to bulk charge.
• Bulk Charge: A high current state, selected by the maximum current setting (Fuse Jumper), controlled by battery voltage. The charger provides maximum current, limited by the circuit, power supply voltage, and battery impedance.
• Peak Voltage (Absorption State): The battery is charged with a voltage limit elevated to 13.8 V or 14.2 V, until current diminishes to one-tenth of the maximum setting. At this current, the charger changes to the float state.
• Float (Maintenance State): The resting state of a charged battery. The charger supplies sufficient current, up to the maximum selected current, to keep the battery at the float voltage of 13.5 V.

State Switching:

Turn-on: If the power supply is turned on and the battery was discharged below 10 volts, the charger starts in trickle charge. If the battery rises above 10 volts, it enters bulk charge. If voltage rises above 12 volts, peak voltage state is entered. When current diminishes to one-tenth of the maximum setting, the float state is entered. If the battery is charged to over 13 volts, turning on the power supply will cause the charger to remain in the float state.

This turn-on cycle occurs following a power outage.

Discharging Battery

If a load is placed on the battery, and the charger was in the float state, and the battery voltage stays above 13 volts, the charger will remain in the float state supplying up to full current. If the battery voltage is discharged to less than 12 volts, and the load is removed, the charger will enter the peak voltage and then the float state.

If the radio station is connected directly to the battery and not through the Super PWRgate output, the battery will supply the load while being charged. Current will be shared between the load and the battery. This method was described by W1ZR in QST, Dec 2003. See the diagram below for the aW1ZR configuration.

LED Indicators

• ? Green (ON): Indicates the charger is fully active and will provide up to maximum current to the battery according to its state. This LED indicates the charger's state ("fully active state and would charge a battery if it were connected"), not current flow.
• ? Green (ON) and ? RED (PK): Indicates the charger is in the peak voltage state (PK) and will provide up to maximum current. As current diminishes, the charger attempts to reach an elevated battery voltage. When current drops to one-tenth the maximum setting, the state changes to float.
• ? Green (ON) and ? Yellow (FL): Indicates the charger is in the float state (FL) and will provide up to maximum current to maintain the battery at the float voltage of 13.5 volts.

A typical charging curve is shown in the figure.

Choosing and Setting the Maximum Charge Current

The charger has three internal current sensing resistors for determining the maximum current limit. 40A fuses are used as the high current switch (a high current jumper wire is needed; the 40A fuse approximates a true jumper). Leaving the fuses out provides a charge current of 1 ampere. To get different charging current values, install fuses as follows:

• 1 Ampere: No fuse
• 4 Amperes: Fuse in left socket
• 7 Amperes: Fuse in right socket
• 10 Amperes: Fuse in both sockets

Use the following charging current for lead-acid battery ratings:

• Use 1 ampere for batteries from 3 to 12 Ah.
• Use 4 amperes for batteries from 13 to 32 Ah.
• Use 7 amperes for batteries from 33 to 50 Ah.
• Use 10 amperes for batteries from 51 Ah up.

Advanced Charger Considerations

Gelled Cells

The battery charger uses the station power supply, typically 13.8 volts for ham radio operators. Circuit components limit the peak charge voltage to around 13.6 volts, slightly less than the desired 13.8 volts for a gelled cell's peak, resulting in a slightly low absorption state. The battery's charge will be a few percent less than maximum available ampere-hours.

To achieve optimum charging, adjust the power supply to 14.10 volts DC. The charger will then permit the battery to reach a peak voltage of 13.8 volts during the peak voltage cycle. The float state will remain at 13.5 Volts.

Note: Always use an accurate digital display voltmeter for accurate readings.

AGM Cells

The charger can be configured for an AGM type sealed battery. To do this precisely, readjust the power supply to provide 14.50 volts. Additionally, install a jumper at J1 inside the Super PWRgate. Remove the top cover. Lift the small blue jumper block off the pin and reinstall it shorting the two pins. The charger will then permit the battery to reach a peak voltage of 14.2 volts during the peak voltage cycle. The float state remains at 13.5 volts.

Note: Always use an accurate digital display voltmeter for accurate readings.

Most major radio manufacturers specify that their radios operate up to 15 Volts DC. Therefore, using the Super PWRgate at an elevated voltage of 14.5 volts is acceptable.

Specifications

Powerpole® Wiring Guide

Additional Resources for Anderson Powerpoles: www.andersonpower.com

Details and a video demonstration for using PWRcrimp Tool with powerpoles: www.westmountainradio.com/crimptool

DCtoGO Battery Box w/ RIGrunner 4008 and Super PWRgate PG40S Warranty

The DCtoGO model is warranted against failure due to defects in workmanship or materials for one year after the date of purchase from West Mountain Radio. The warranty does not cover damage caused by abuse, accident, misuse, improper or abnormal usage, failure to follow instructions, improper installation, alteration, lightning, or other incidence of excessive voltage or current.

If failure occurs within this period, return the DCtoGO model or accessory to West Mountain Radio at your shipping expense. The device or accessory will be repaired or replaced, at West Mountain Radio's option, without charge, and returned at their shipping expense. Repaired or replaced items are warranted for the remainder of the original warranty period. You will be charged for repair or replacement of the Super PWRgate PG40S or accessory made after the expiration of the warranty period.

West Mountain Radio shall have no liability or responsibility to the customer or any other person or entity with respect to any liability, loss, or damage caused directly or indirectly by use or performance of the products or arising out of any breach of this warranty, including, but not limited to, any damages resulting from inconvenience, loss of time, data, property, revenue, or profit, or any indirect, special incidental, or consequential damages, even if West Mountain Radio has been advised of such damages.

Except as provided herein, West Mountain Radio makes no express warranties, and any implied warranties, including fitness for a particular purpose, are limited in duration to the stated duration provided herein.

Contact Information:

West Mountain Radio
www.westmountainradio.com
1020 Spring City Drive, Waukesha, WI 53186
tel 262-522-6503 fax 262-522-6504