Thank you for your purchase of the Power Badger product!
The Power Badger was engineered to be rugged, long lasting and easy to use. We are grateful you have put your trust in our company and chosen to invest your hard-earned money in our product.
Table of Contents:
Page 1 (this page)
Page 2-3: Initial plug-in, setting-up your Badger for the first time
Page 4:Power Badger Operation and Hidden Displays
Page 5-6: General Information
Page 7: Power Badger Term Definitions
Page 8: Device MapPage
Page 9: Device Features
Page 10: Parts List
The first time you plug in your Power Badger you will be prompted to make a few initial settings These settings will be saved (via the Badger’s internal battery) for a period of 4-6 months, so you don’t have to make these setting selections more than once per winter season and you don’t have to set it up outside in the cold. You can set-up your Badger indoors and then bring it outside when ready to use. All your settings will be saved.
Follow the steps below (in the sequence given) to set up your Badger for the first time:
1). Plug in the device: Display flashes “12:00” in conjunction with the “Current Time” LED indicator.
2). Set current time:
Use the up/down selection buttons (on the right side of the device) to select the current time. Note: there is a “PM” indicator in the lower right corner of the display that will illuminate when a PM time is selected. If the “PM” indicator is not illuminated, then the time displayed is AM time. Once desired time is selected, press the “Set” button. The current time is now saved and the device prompts you to make a temperature units selection; see next step.
3). Select degrees Celsius (°C) or degrees Fahrenheit (°F):
Use up/down selection buttons to toggle between °C and °F
Once the unit type you wish to use is displayed, press the “Set” button. The temperature units selection is now saved and the device display now flashes “12:00” in conjunction with the “Ready Time” LED indicator; prompting you to set the time you desire the unit to have your engine ready to start; see next step.
*(*If you only intend to use your Power Badger in the “Maintain” mode, you may press the “Set” button to bypass setting the “Ready Time”,… then skip to step 5.)
4). Set the desired “Ready Time”:
Use the up/down selection buttons to select the desired “Ready Time”. This will be the time that you want your engine ready to start (be sure to mind the “PM” indicator for setting PM times).
Once desired “Ready Time” time is selected, press the “Set” button. The current time is now saved and the device displays “2 HR” and flashes the “Maintain Ready” LED, prompting you to make a “maintain after ready” selection of between 0 and 9 hours.
5). Set the “Maintain after ready” duration:
This selection controls how long the unit maintains your engine in a “ready to start” condition after your selected “Ready Time” has been reached (settable at 0-9 hours).
*Example: If you have the “Ready Time” on your Badger set to 6:00am, the “maintain after ready” duration you select (0-9 hours), controls how long your unit will go into “Maintain” mode after 6:01am. If you select “3HR” then your engine will be put in “Maintain” mode for 3 hours after the ready time….so, in this example of “3HR” selected, the engine would be maintained in a ready to start condition until 9:00am. 9 hours is the maximum amount of time the unit can be set to maintain after a “Ready” event. If longer than a 9 hour maintain duration time is desired, the Badger can be put permanently in “Maintain Mode”, as discussed later in this manual.
To select the desired “maintain after ready” duration, use the up/down selection buttons to make your selection of 0-9 hours. Once you have made your selection, press the “Set” button and the unit will display “OFF”. This concludes the user defined selection and setting process.
6). Set your desired Mode:
Next, using the “Mode” button, you will set the mode that your Badger will operate in. Each press of the mode button will scroll to the next operational mode of the device. Illustrations below show examples of what the screen and LED’s will look like in each of the 4 modes:
See General Operation section (next page) for further information on modes.
Times Ready Mode:
Maintain Ready Mode:
Press the “Mode” button, to toggle through the 4 different modes of your Power Badger. Each press of the Mode button will scroll to the next choice. Once the desired choice is displayed, no further action is needed, the device is then in that mode of operation.
Your choices are:
1). OFF: unit is powered and ready but will take no action.
2). Timed Ready: The device will have your engine ready to start at your set “Ready Time”. The “Timed Ready” LED will remain illuminated. The time related LED’s and display will cycle through the following sequence when in this mode: current time, ready time, current temperature.
3). Maintain Ready: The device will maintain your engine in a ready-to-start condition in perpetuity. The “Maintain Ready” LED will remain illuminated and the display will scroll the current temperature and “rEdy”, indicating the engine is being maintained in a ready-to-start condition.
4). Constant ON: The device will supply constant power to the heater without further control(in perpetuity).
More information on each particular mode can be found on page# 7 (Power Badger Term Definitions).
Hidden Menu Display Readouts:
The hidden readouts are only accessible when the device is in the “Constant ON” mode and red “heater on” LED indicator is illuminated:
Location:The Power Badger unit must be in approximately the same temperature environment as the engine heater it will be controlling. It is best to keep the unit out of direct sunlight, as the direct sunlight can affect the measured temperature readings at the unit. If the vehicle being controlled is in the direct sunlight, then just underneath the vehicle it is controlling is a good spot for the Badger. The Badger calculates firing times and duration algorithms based upon temperature readings in its ambient environment. If the observed temperature at the Power Badger is different than where the engine is located, then the calculations will not be as intended and the result could be an engine that is not as ready to start as intended.
Internal Battery: The Power Badger contains an internally mounted lithium battery (CR2032) that allows the unit to save the user settings for a period of up to 6 months without external power. Once this battery becomes depleted and user settings (such as the current time) are no longer retained, it will be necessary to replace the internal battery.
Battery Change Instructions: The internal battery is a standard CR2032 button cell, readily available at most battery retailers.
To replace the internal memory retention battery:
Internal Fuse: The Power Badger is equipped with an internal fuse to keep your unit safe in the event of an overload condition. Common causes of an overload condition can be:
a). more than 1800 watts of load on the Badger
b). failed/electrically shorted engine heating element
c). internal water intrusion into the Badger’s enclosure
Internal Fuse Change Instructions: The internal fuse is a standard 20 amp 250v (Bel Fuse#3AB20 or Littelfuse#0314020.MXP) readily available at most electrical parts retailers.
To replace the internal fuse:
Wind: High wind conditions can take heat from the engine compartment and make the engine more difficult to warm. It is preferable to protect the vehicle’s engine from the wind as much as possible. Even putting the front of the vehicle near the wall of a building or other vertical surface higher than the grille can help maintain engine heat.
Heaters Type: The Power Badger Model 1800US is designed to power up to 1800 watts of resistive type load, such as: Engine block heaters, Battery blankets/pads, Oil, fuel and Oil pan mounted heaters. These heaters must be suited to their application and sized properly for their intended use, otherwise dangerous conditions could result. Regardless of whether the Power Badger to controls these devices or not, the heaters installed on a vehicle or on/in an engine must be sized and suited properly for their application.
In the Event of a Power Outage: If power is interrupted during operation, once the power returns, the Power Badger is programmed to continue the same mode of operation as it was in when the power failed. If the unit was in “Timed Ready” mode when the power failed, the unit will resume operation to ready the engine for its intended start time, but if the power outage was too long, the unit may not have enough time to fully prepare the engine to start as intended. In the same way, if the unit was in “Maintain Ready” mode when the power failed (and the power was out for too long)the unit may not be able to restore the engine to a “start-ready” state (depending upon the ambient temperature).
Maintain after ready:
This selection controls how long the unit maintains your engine in a “ready to start” condition after your selected “Ready Time” has elapsed. This is a user selectable parameter of between 0 hours and 9 hours.
*Example: If you have the “Ready Time” on your Badger set to 6:00am, the “maintain after ready” duration you select (0-9), controls how long your unit will go into “Maintain” mode after 6:01am. If you select “3HR” then your engine will be put in “Maintain” mode for 3 hours after the ready time….so, in this example of “3HR” selected, the engine would be maintained in a ready to start condition until 9:00am. 9 hours is the maximum amount of time the unit can be set to maintain after a “Ready” event. If longer than a 9 hour maintain duration time is desired, the Badger can be put permanently in “Maintain Mode”, as discussed later in this manual.
“Ready Time” is a user defined setting, defining at what time the Power Badger device will aim to have the engine ready to start. The device will use the (user defined) ready time along with the outside temperature measurements to calculate when to fire the engine heater and for how long.
Maintain Ready Mode:
The function of the “Maintain Ready” mode is to keep (or maintain) an engine that is already ready to run in a startable condition (ie..vehicle was just parked after running or was just brought up to temperature by the “Ready” mode). The Power Badger device senses the outside temperature and calculates a firing duty cycle algorithm designed to use the minimum amount of electricity necessary to maintain the engine in a startable condition. To achieve this, themicroprocessor inside the Badger divides that cycle into segments ofon and off, based upon the measured outside temperature. The Badger will automatically maintain the engine in a startable condition, in perpetuity, until changed or unplugged.
The Power Badger was carefully engineered to be rugged and long lasting. We want the owners of the Power Badger to know that their unit is well built. We assemble every unit right here in North Carolina, USA, using no-compromise, high quality components that (in many cases) were engineered and produced specifically and exclusively for the patent pending Power Badger product. The Power Badger has been extensively tested for functionality and durability down to -50°F / -45°C.
Here we list some of the features and details of the product that may not be readily apparent at first glance:
Power Badger Model# 1800US Replacement Parts List
|Part number||Description||Qty per unit|
|PB1001||Enclosure / Housing||1|
|PB1002||Bottom / back aluminum cover||1|
|PB1003||Front membrane / face||1|
|PB1006||PCBA assembly, w/blue display||1|
|PB1007||Input power cord / 120v / male||1|
|PB1008||Output power cord /120v / female||1|
|PB1009||Thermistor / temperature sensor||1|
|PB1010||Input/output cord strainer M20 / black||2|
|PB1011||Thermistor cord strainer / M16 /grey||1|
|PB1018||Bottom / back cover stainless mounting screw||6|
|PB1019||Bottom / back cover to enclosure, molded gasket||1|
|PB1021||Front membrane / face, stainless nails||4|
© Bostic Motors Inc. 2017 (all rights reserved)
157 N Main St.
Bostic, NC 28018
Limited Warranty - This limited warranty is expressly limited to Bostic Motors Inc’s products (hereafter referred to as “The Company”) that have been purchased by the original consumer purchaser or for purposes of resale or in the ordinary use by the end-user. The term original consumer (end-user) purchaser is defined as the person who purchases Company products for personal, residential or business use.
The Company's products are warranted against defects in materials and workmanship for a period of one year from date of purchase by consumer / end-user. The exclusive remedy for any product found to be defective during this limited warranty period consists of the repair or replacement of the defective product. This limited warranty does not apply to defects which arise from normal wear and tear, accident, misuse, abuse, neglect, mishandling, misapplication, faulty installation, modification, improper or extraordinary use or use inconsistent with any instruction or recommendation issued by the Company.
The foregoing limited warranty is exclusive and in lieu of all other warranties, whether written or oral, express, implied or statutory.
NO IMPLIED WARRANTY OF MERCHANT ABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY. THE LIMITED WARRANTY CONTAINED HEREIN DOES NOT EXTEND TO INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF THIS PRODUCT, OR ARISING OUT OF A BREACH OF THIS WARRANTY.
To obtain performance of this limited warranty, the alleged defective product must be returned, together with reasonable proof of purchase, written explanation of the problem and postage or freight prepaid, directly to:
In U.S.A & Canada:
Bostic Motors Inc, Attn: Warranty Claims
157 North Main St.
Bostic, NC 28018
The Company will return the repaired or replaced product, postage or freight prepaid. Final determination of defects shall be made in accordance with procedures established by the Company.
This limited warranty gives the original consumer purchaser specific rights. You may have other rights which vary from state to state or province to province depending upon the location of your residence. Some states do not allow the exclusion or limitation of incidental or consequential damages.
Manufacturer's rights retained: The Company reserves the right to make changes in design, additions or improvements to any of Its products at any time without incurring any obligation whatsoever to install or replace the same or improve upon products previously manufactured.
Bostic Motors Inc. - Rev. 09/2017