12/24V 70A MANUAL WORKSHOP BATTERY CHARGER

12/24V 70A MANUAL

P/No. HDBC90

WORKSHOP

BATTERY CHARGER

2

IMPORTANT SAFETY INFORMATION Please read this manual thoroughly before use and store in a safe place for future reference.

WARNING•Explosivegases.Preventflamesandsparks.Provideadequateventilationduringcharging.

•Beforecharging,readtheinstructions.

•Forindooruse.Donotexposetorain.

•ForchargingleadacidbatteriesONLY(ofthesize&voltagespecifiedinthespecifications table).

•Alwayschargethebatteryonthecorrectvoltagesetting.Neversetthecharger toahighervoltagethanthebattery.

•Disconnectthe240Vmainssupplybeforemakingorbreakingtheconnections to the battery.

•Thebatterychargermustbepluggedintoanearthedsocket-outlet.

•ConnectiontosupplymainsistobeinaccordancewithNationalwiringrules.

•Donotattempttochargenon-rechargeablebatteries.

•Neverchargeafrozenbattery.

• IftheACcordisdamageddonotattempttouse.Itmustbereplacedorrepaired byaqualifiedperson.

•Corrosivesubstancesmayescapefromthebatteryduringcharginganddamage delicate surfaces. Store and charge in a suitable area.

•Ensureallvehicleaccessoriesincludinglights,heaters,appliancesetcareturnedoff prior to charging.

•Thischargerisnotintendedforusebypersons(includingchildren)withreducedphysical,sensoryormentalcapabilities,orlackofexperienceandknowledge,unlesstheyhavebeengivensupervisionorinstructionconcerninguseoftheapplianceby a person responsible for their safety.

•Youngchildrenshouldbesupervisedtoensurethattheydonotplaywiththeappliance.

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FEATURESENGINE START FUNCTION

Startsvehicle’swithaflatbatteryafteracontrolled5minutecharge.

CHARGE METER ClearlydisplaystherateofchargeinAmpstoensureanaccurateandthoroughcharge.

ADJUSTABLE OUTPUT Adjusttherateofchargetobestsuitdifferentbatterysizes.

RAPID CHARGE Increaseschargerateforashortpowerfulcharge.

MULTI VOLTAGE OPERATION Suitableforcharging12V&24Vbatteries.

0–60MIN TIMER Automaticallyturnsthebatterychargeroffafterasettimewhenchargingyourbattery

inRapidChargemode.

POLARITY PROTECTION Fuseprotectionpreventsdamagetothechargerintheeventofreversepolarityand

short circuit.

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SPECIFICATIONS P/No. HDBC90

TYPE Manual

INPUT 240V,50Hz,2000W

OUTPUT 9.0Aat12V(setting1) 11.0Aat24V(setting1) 23.0Aat12V(setting2) 27.0Aat24V(setting2)

60.0Aat12V(setting3) 60.0Aat24V(setting3) 70.0Aat12V(rapidcharge) 70.0Aat24V(rapidcharge)

ENGINESTART 3secon,2minoff 12V 24V 360Aat6V 360Aat12V

MINIMUMSTART 0.0V VOLTAGE

BACKDRAIN 12V 24V 5.5mA 11.6mA

APPROVALS ElectricalSafety,EMC

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BATTERY CHARGER ASSEMBLY YourHDBC90isshippedwiththefollowingpartswhichrequireassemblytothemain

body of the battery charger unit:

•1xBatteryChargerHandle

•4x50mmScrews

•1xBottomStabiliserStop

•2x50mmSelfTappingScrews

•2xTrolleyWheels

•WheelAxle

•2xBlackVoltageTerminalCaps

•2x35mmWashers

•2xWheelLockingRings.

1.Placethemainbodyofthebatterychargerinanuprightposition,installthetophandleofthebatterychargerusingthe4x50mmscrewsasperthebelowillustration.UseaPhillipsheadscrewdrivertotightenall4screws.

2.Laythemainbodyofthebatterychargerdownflatandfitthestabiliserstoptothebottomofthebatterychargerusingthe2x50mmselftappingscrewsprovided.Use aPhillipsheadscrewdrivertotightenscrews.

3.Placethewheelaxleprovidedthroughthebottomofthebatterychargerasperthebelowillustration.

4.Placethe2x35mmwashersoneither endoftheaxle.

5.Fitthe2trolleywheelstoeitherendof theaxleandsecurewiththe2xwheel lockingring’sprovided.

6.Screwthe2xblackvoltageterminal capsprovidedtoboththe12V& 24Voutletsonthetoppanelofthe battery charger.

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ASSEMBLING CHARGING LEADS TO BATTERY CLAMPS TheHDBC90batterychargerisshippedwiththebatteryclampsdisconnectedfromthe

positive&negativechargingleads.

IMPORTANT:•Thenegative(Black)batteryclampmustbeconnectedtothecharginglead

connectedtotheunit.

•Thepositive(Red)batteryclampmustbeconnectedtothebarecopperend ofthesecondchargingleadsupplied.Connecttheoppositeendofthechargingleadtoeitherthe12Vor24Voutletonthetoppanelofthebatterycharger viathecablelugontheendofthecharginglead.

Toconnectboththepositiveandnegativeleadstothebatteryclampsrefertoinstructionsbelow:

1.Slidetherubbercoveroffthebatteryclamphandle.

2.Loosentheboltlocatedontheoutsideofthebatteryclamphandleusinga10mmsocket.

3.Feedthebearcopperendofthebatteryclampleadthroughthebatteryclamphandleandpositionunderneaththerectangularnutaspertheillustrationbelow.

4.Refit&tightenbolttocreatefirmconnection.

5.Slidetheplasticcoverbackoverthebatteryclamphandle.

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CHARGING INSTRUCTIONSSTEP 1 – CHECK THE ELECTROLYTE LEVEL

Priortochargingthebattery,removetheventcapsandchecktheelectrolytelevel.(Notrequiredonsealed&maintenancefreebatteries).Theelectrolyteshouldbe6mm(1/4”)abovethebattery’splates.

Iflow,topuptheelectrolytewithdistilledwatertothecorrectlevelandrefittheventcaps.

STEP 2A – CONNECTION OUT OF VEHICLE ConnecttheREDlead(batteryclip)fromthechargertothePositive(+)batterypost.

ConnecttheBLACKlead(batteryclip)fromthechargertotheNegative(-)batterypost.

CONNECTIONOUTOFVEHICLE

STEP 2B – CONNECTION IN VEHICLE DetermineifthevehicleisPositively(+)orNegatively(-)earthed.Negativelyearthed

vehicleshaveacable(usuallyblack)fromtheNegativebatteryterminaltothevehicle’schassis.

NEGATIVELY EARTHED (MOST VEHICLES) ConnecttheREDlead(batteryclip)fromthechargertothePositive(+)batteryterminal.

ConnecttheBLACKlead(batteryclip)fromthechargertothevehicle’schassisawayfromthefuellineormovingparts.

CONNECTIONINVEHICLE(NEGATIVELYEARTHED)

12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE STARTWORKSHOP 7000


A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V

8

POSITIVELY EARTHED ConnecttheBLACKlead(batteryclip)fromthechargertotheNegative(-)batteryterminal.

ConnecttheREDlead(batteryclip)fromthechargertothevehicle’schassisawayfromthefuellineormovingparts.

CONNECTIONINVEHICLE(POSITIVELYEARTHED)

STEP 3 – CONNECT TO 240V MAINS POWER Ensure‘CHARGERATE’dialisturnedtoOFF&connectthebatterychargerto240V

mainspower.

STEP 4 – SET BATTERY VOLTAGE Setthevoltageofthebatterychargerbyremovingtheblackterminalcapfromeitherthe

12Vor24Vterminalonthetoppanelofthejumpstarter.Connectthepositivebatterycableviatheringterminaltotheappropriate12Vor24Voutlet.Ensurethebatterychargervoltageissettothesamevoltageasthebatterybeingcharged.

STEP 5 – SET THE CHARGE MODE

NORMAL CHARGE RATE ADJUSTMENT Thenormalchargeratecanbeadjustedbyturningthe‘CHARGERATE’dialonthetop

paneloftheunittosetting1,2or3.Thechargerateshouldbesetaccordingtothesizeof the battery.

Seetherecommendedchargeratesforvariousbatterysizesinthetablebelow:

CHARGERATE BATTERYSIZE

DeepCycle(Ah) Automotive(CCA) Marine(MCA) Time(Hours)

Setting1(12V) 60–180 380–1080 520–1500 7–24

Setting1(24V) 75–220 460–1300 640–1830 7–24

Setting2(12V) 160–460 670–2800 1340–3800 7–24

Setting2(24V) 190–540 1130–3240 1600–4500 7–24

Setting3(12/24V) 420–1200 2500–7200 3500–1000 7–24



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V



A

FUSE 2 x 100A

POWER ON

3

1020

3040

5060

12V 24V

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RAPID CHARGE Turnthe‘CHARGERATE’dialonthetoppaneloftheunitto‘RAPIDCHARGE’&setthe

timerbetween0-60min.TheRapidChargefunctionwillprovidea70Achargetoyourbatteryidealforwhenashortpowerfulchargeisrequired.

STEP 6 – CHARGING Duringcharging,theChargeMeter’sneedlewilldecrease

towardstheleft.Afullychargedbatteryisindicatedbyaverylowreadingaccordingtothebattery’scapacityandcondition.

Oncethispointhasbeenreached,proceedtodisconnectthebattery(ReferSTEP7“DISCONNECTION”).

Important: ChargingwillcontinueuntiltheOn/OffswitchisturnedtoOFF.

Thebatteryandchargermustbemonitoredtoensurethebatteryisnotovercharged.

Oncecharged,theliquidinsidethebatterymaystarttoboil.Itisrecommendedtostopchargingwhenthisoccurstopreventdamagetothebattery.

STEP 7 – DISCONNECTION Turnthe‘CHARGERATE’dialtothe‘OFF’positionanddisconnectchargerfrom

the240Vsupply.

Batteryoutofvehicle RemovetheBLACKlead(batteryclip)fromthebattery.RemovetheREDlead(battery

clip) from the battery.

Batteryinvehicle Removethechassisconnection.Removethebatteryterminalconnection.

ChargeMeter

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ENGINE START FUNCTIONSTEP 1 TO 4 – FollowSTEPS1to4ofthecharginginstructionsofthisbooklet.

STEP 5 – Turnthe‘CHARGERATE’dialtothe‘RAPIDCHARGE’function,andsetthe‘TIMER’dialto5minutesandallowchargertochargethevehiclesbattery.

STEP 6 – Oncethe5minuteRapidChargeiscomplete,turnthe‘CHARGERATE’ dialto‘ENGINESTART’.

STEP 7 – Turnthevehicle’signitionkeytostarttheengine.

STEP 8 – Ifenginefailstostartafter3secondsrepeatinstructionSTEP5&6beforeattempting to start the engine again.

NOTE:Donotrepeatthisoperationmorethan5times.

NOTE:WheninenginestartmodetheHDBC90usesincreasedpowerforashortperiodoftime.Ensureotherappliancesconnectedtothatpowercircuitareturnedofftoavoidfuseorcircuitbreakeroverloadinthebuildingsswitchboard.

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PRODUCT OVERVIEW

PositiveBatteryClamp

NegativeBatteryClamp

TrolleyWheels

BottomStabiliserStop

ChargeMeter

Charge/EngineStart/OffSwitch

ChargeTimer

PowerOnIndicator

240VMainsPowerCord

12V/24VTerminals

OutputFuse

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HOW TO CHANGE OUTPUT FUSE Thebatterychargerisfittedwith2x100Afusesdesignedtoprotectthebattery

chargeragainstreverseconnection&shortcircuit,thefuseislocatedonthetoppanelof the battery charger.

Toreplaceblownfuses:

1.Disconnectbatterychargerfrom240Vmainspower.

2.Disconnectbatterychargerleadsfromthevehiclesbattery.

3.Removefusecoveronthetoppaneloftheunit.

4.Removeandrefitfuses(ProjectaP/No.HDBCF100A)usinga10mmsocket.

5.Refitfusecover.

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FREQUENTLY ASKED QUESTIONSQ.HowdoIknowifthebatteryisfullycharged?A.TheChargeMeter’sneedlewilldecreasetowardstheleft.Afullychargedbatteryis

indicatedbyaverylowreading.RefertoSTEP6ofthecharginginstructionsforanillustrationoftheChargeMeter.

AlternativelyuseaBatteryHydrometer(ProjectaPartNo.BH100).Areadingof1.250 or more in each cell indicates a fully charged battery.

Q.WhydoestheChargeMeterindicateafullychargedbatterystraightaway?A.TherearefourpossiblereasonswhytheChargeMetermayindicateafullycharged

batterystraightaway.

1. Thebatteryisfullycharged.

2. Thebatteryhastakenasurfacecharge.

3. Thebatteryhasafaultycell.

4. TheBATTERYVOLTAGEsettingonthechargerissetlowerthanthebatteryvoltage.

Q.WhatisSurfaceCharge?A.Batteriesunusedorleftflatforsometimebuilduparesistancetobeingrecharged.

Whenthechargerisfirstconnected,thesebatterieswilltakeasurfacecharge,andtheChargeMeterwillindicateafullychargedbatterywithinashortwhile.Thebatteryhoweverisnotfullycharged,thechargerisvoltagesensitiveandcannotdifferentiatebetweenasurfacechargeandafullychargedbattery.Afterafewhoursthebatterymaystarttoacceptsomechargebutmostbatterieswiththisconditionwillnotrecover.

Q.WhatisaFaultyCell?A.12Voltbatteriescontain6cellsandonefaultycellisenoughtoruinyourbattery.

Ifaftereighthoursofchargingyourbatteryisstillflat,youshouldtestthecellsusing ahydrometer.Ifonereadingislowerthantherestitindicatesafaultycell.Itispointlesstocontinuecharging,asthebatteryneedsreplacing.

Q.CanIusethechargerasapowersupply?A.No.TheHDBC90cannotbeusedasapowersupply.Donotattempttoconnectthe

clamps to anything other than a suitable battery.

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Q.WhatareVoltsandAmps? VOLTS

Thetermvoltagereferstotheelectricalforceorelectricpotentialtodoworkbetweentwoterminalsoragoodanalogyiswaterpressureinapipe.Forexampleabatteryhas12Voltsbetweenthepositiveandnegativeterminals,ora6Voltbatteryhas6Voltsbetweenthepositiveandnegativeterminals.

AMPS

ThetermAMPSistheunitofmeasureusedforcurrent.Thiscanbedescribedastheflowofelectricchargeinacircuit.Againifyouusethewateranalogythiswouldrefertohowmuchwaterisflowingthroughthepipe.Forexampleifthecurrentisreading 12Ampsthenthisistheamountofenergygoingintothebattery.

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NOTES:

Distributedby

AUSTRALIABrown&WatsonInternationalPtyLtdKnoxfield,Victoria3180Telephone (03)97306000Facsimile (03)97306050NationalTollFree 1800113443

NEWZEALANDNarvaNewZealandLtd22–24OliveRoadPOBox12556PenroseAuckland,NewZealandTelephone (09)5254575Facsimile (09)5791192

IS166Issue21.6.12

WARRANTY STATEMENT Brown&WatsonInternationalPtyLtd(“BWI”)of1500FerntreeGullyRoad,Knoxfield,

Vic.,telephone(03)97306000,fax(03)97306050,warrantsthatallproductsdescribedinitscurrentcataloguewillundernormaluseandservicebefreeoffailuresinmaterialandworkmanshipforaperiodofone(1)yearfromthedateoftheoriginalpurchasebythecustomerasmarkedontheinvoice.Thiswarrantydoesnotcoverordinarywearandtear,abuse,alterationofproductsordamagecausedbythepurchaser.

TomakeawarrantyclaimtheconsumermustdelivertheproductattheircosttotheoriginalplaceofpurchaseortoanyotherplacewhichmaybenominatedbyeitherBWIortheretailerfromwheretheproductwasboughtinorderthatthewarrantyassessmentmaybeperformed.Theconsumermustalsodelivertheoriginalinvoiceevidencingthedateandplaceofpurchasetogetherwithanexplanationinwritingastothenatureoftheclaim.

IntheeventthattheclaimisdeterminedtobeforaminorfailureoftheproductthenBWIreservestherighttorepairorreplaceitatitsdiscretion.Intheeventthatamajorfailureisdeterminedtheconsumerwillbeentitledtoareplacementorarefundaswellascompensation for any other reasonably foreseeable loss or damage.

ThiswarrantyisinadditiontoanyotherrightsorremediesthattheconsumermayhaveunderStateorFederallegislation.

IMPORTANTNOTE OurgoodscomewithguaranteesthatcannotbeexcludedundertheAustralianConsumer

Law.Youareentitledtoareplacementorrefundforamajorfailureandcompensationforanyotherreasonablyforeseeablelossordamage.Youarealsoentitledtohavethegoodsrepairedorreplacedifthegoodsfailtobeofacceptablequalityandthefailuredoesnotamounttoamajorfailure.

12/24V 70A MANUAL WORKSHOP BATTERY CHARGER

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