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1. connection Check the output wires crocodile clips for loose damaged connection indication Battery 2 YEAR MANUFACTURER WARRANTY Zylux Distribution Pty Ltd OzCharge warrants to the Customer that this product is substantially free from defects in materials and workmanship under normal use for a period of 2 Years from the Date of Purchase Please ensure you keep a copy of your receipt on file as this will be required for proof of purchase and to validate your warranty Obtaining Warranty Service Within the warranty period the Customer must contact the authorised supplier retailer where the product was purchased or alternatively you can contact the OzCharge service centre through one of the following methods Hotline 03 9482 2203 Website www ozcharge com au If the Authorised Supplier and or OzCharge service centre concludes that while under normal use a product failure or malfunction occurred during the warranty period and was caused by a defect in material or workmanship see Exclusions the Customer will be asked to ship to the nearest service point The product must be packaged appropriately for safe shipment To prove that the product is under warranty the customer should enclose a copy of their receipt for proof of purchase It is recommended that returned products be sent by registered mail as Zylux Distribution Pty Ptd OzCharge accepts no responsibility liability for goods lost or damaged in2. Switching mode with Micro controlled Designed and Made for Australian Conditions Input 220 260Vac Output 12Volt DC User s Manual and Important Safety Information Model OC SW121040 OC SW121060 FEATURES Congratulations on purchasing an OzCharge Automatic Switching Mode Battery Charger OzCharge Battery Chargers comprise of the latest technology and they incorporate the following features High frequency Switching Mode Full time pulse charge output Microprocessor controlled Multi charging rate Selectable Suits Lead Acid Battery Types Calcium Conventional Sealed WET GEL Selectable Battery rejuvenation De Sulphation function Selectable Heavy duty cables Corrosion resistant output connectors and clamps Designed for Australian Conditions This charger is designed for indoor use only and should never be exposed to rain Make sure you are using proper AC line power voltage Do not attempt to use the charger if it has been dropped or damaged Never attempt to charge a damaged battery frozen battery or non rechargeable battery Do not use the charger in a closed area or poorly ventilated area Never smoke use an open flame or create sparks near a battery or charger during charging operation as this may cause an explosion explosive gas Do not operate the charger if the cord or plug is damaged Do not disassemble the charger Take it to a qualified person if a repair is required Keep the charg
3. Indicated by a BLUE LED Full Charging eAbsorption This stage charges the battery using a constant voltage providing that the Battery Voltage is over 85 The Charging Voltage for this stage is determined by the Battery type selection GEL 14 1V AGM WET 14 4V Calcium 14 7V Indicated by the Absorption LED ON eEqualising This stage begins automatically if the Calcium Battery type has been selected This cycle pushes the charge voltage up to an equalising level of 16 2V Indicated by the Absorption Green LED Flashing Full Charging eAnalysis Diagnoses the battery condition for ten minutes If the Full LED is flashing this indicates that the battery is still less than 12 5V after the absorption mode and that there is a fault with the battery Indicated by the FULL LED Flashing eFull Float Battery is fully charged and is ready for use It will be maintained at a safe constant voltage Battery type selection GEL 13 8V AGM WET 13 8V Calcium 13 8V Indicated by the Full LED ON Rejuvenation Process EXTEND YOUR BATTERY LIFE Full Charging Rejuvenation Your OzCharge Battery Charger provides a battery rejuvenation function What does this feature do Rejuvenation has been proven to break down the crystalline form of lead sulphate within the battery cells which helps extend your battery life We recommend that you periodically use this rejuvenation De Sulphate feature to ensure you get the maximum li
4. H65mm OC SW121040 8 OC SW121060 5 TROUBLE SHOOTING Problems Indication Possible causes Suggest solution Charger does Indicator lights are not No AC power Check AC connections and make not work on sure Power Point is switched ON Charger has no DC output Fault LED is Flashing Output is short circuited Output cables are not connected to the battery Output Reverse polarity connection Check DC connection between charger and battery and make sure they are not short circuiting Check that the crocodile clips haven t fallen off the battery Check that the crocodile clips ring terminals are connected to the correct polarity No Charging Current Long charging time Full light does not come on Fault LED is ON Fault LED is ON Battery is severely sulphated Battery has a damaged cell Charger overhead protection mode Wrong battery type selected Battery capacity too large Battery is defective 6 hours soft start timer reached 24 hours bulk charge timer reached Check the Battery condition age etc If battery cannot be rejuvenated it must be replaced Move battery amp Charger to cooler environment Check the charging rate and battery type selection matches the battery Battery cannot be charged and must be replaced Abnormal LED ALL LED s Flash Poor connection from Charger to Check for a loose battery terminal
5. transit Return Shipping costs to be incurred by the Customer Exclusions If upon receiving a product for repair and if testing and examining the product has disclosed that the alleged defect or malfunction in the product does not exist or was caused by the Customer or any third persons misuse physical abuse water damage unauthorised attempts to open repair or modify the product or improper installation this will not be covered under this warranty This Warranty is void if 1 The product has been tampered or repaired by unauthorised personnel 2 The warranty seal is broken or altered 3 The warranty period has expired OPTIONAL ACCESSORIES Model OC SW121040 1 2 4Amp OC SW121060 2 4 6Amp Ring Terminal Connector Model No OC RT 4 6A Distributed by Zylux Distribution Pty Ltd www ozcharge com au Rev 1 06
6. ARGER ne o 2141 6 Amp Model OC SW121060 Hold for 3 sec for rejuvenation 1 Charging Rate Selection Button Press to Select the Current Charge Rate 2 Charging Current LED Display LED indicates the selected charging current 1A or 2A or 4A Model OC SW121040 LED indicates the selected charging current 2A or 4A or 6A Model OC SW121060 3 Battery Type Selection Button Press to select the Battery Type Calcium AGM amp WET or GEL 4 Battery Type LED Display LED indicates the selected Battery Type 5 Charging Status Display LED Dual Colour Charging Process Yellow LED Fully Charged Green LED 6 Charging Fault LED Display See trouble shooting for further details 7 Rejuvenation Stage LED Display Blue Blinking LED Indicates the Rejuvenation Charge RECOMMENDED BATTERY CAPACITY The following minimum AH capacities are to be used as a general guide only Some Batteries maybe able to handle a higher Charge Current Check with the Battery Manufacturer when charging Batteries with small capacity Charge Current 1A 2A 4A 6A Battery Capacity 3 20AH 6 40AH 12 80AH 18 120AH OPERATING INSTRUCTIONS The OzCharge Battery Charger is easy to operate and very simple to use Please refer to the operating instructions below 1 Pre Charge Check a Check the Battery Electrolyte level Non sealed Batteries If necessary remove the vent caps and add distilled wate
7. and Negative Leads are reversed Refer to Trouble Shooting Page for further information b Select the desired charge rate 2A and 4A for small batteries 8A and 10A for medium or deep cycle batteries 16A and 21A for large or heavy duty deep cycle batteries c Select the Correct Battery Type Calcium s the new generation battery Sealed Type VRLA Lead Acid battery with Calcium Content Automotive or Deep Cycle Sealed WET These are the most common and are also known as WET Flooded or AGM Absorbed Glass Mat Sealed valve regulated Lead Acid VRLA Batteries Automotive or Deep Cycle GEL Sealed type VRLA with a jellified electrolyte Automotive Aviation Solar or Deep Cycle Note The charger will automatically memorise your charging rate setting and battery type setting The next time you use the charger it will automatically start with the last settings We strongly recommend that you refer to the battery manufacture s specifications when selecting the charge rate and battery type The Charging process The Charging LED s will indicate the Charging Stages The charging stages are as follows Full Charging eSoft start Charges the battery using half the maximum current until the battery voltage is over 10 5V Indicated by a BLUE LED Soft Start occurs if the initial voltage is less than 10 5V due to deep discharge eBulk Charge Charges using a constant maximum current until the battery rises to the absorption level
8. er away from infants children and pets Switch off the mains power supply before connecting or disconnecting the unit to a Battery CAUTIONS e Refer to the battery Manufacture s specific recommended values to determine your Battery Type and for setting the charging rate e Check the Battery Manufacture s specific precautions such as removing or not removing cell caps whilst charging e Please ensure the correct Battery Type is selected Do not charge using an incorrect Battery Type Setting For example do not charge a Gel battery with Calcium battery selection setting as this may damage your battery e Someone should be within range of your voice or close enough to come to your aid if working near a lead acid battery e Wear protective goggles and turn your face away when connecting or disconnecting a battery e f battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye immediately flush the eye with running cold water for at least 10 minutes and seek medical attention immediately e To reduce risk of damaging the Battery avoid dropping any metal tools onto the battery e Never rest the Battery being charged on top of your OzCharge Battery Charger e The Battery Charger should be kept as far away from the Battery as the output cables permit CONTROL AND INDICATORS Full Fault Charging Rejuvenation gt 6A Calcium mu A gt a BATTERY CH
9. fe out of your battery To activate this rejuvenation feature simply press and hold the Select Battery Type Button for 3 Seconds until the Rejuvenation LED begins flashing YELLOW Once the charger has entered the rejuvenation de sulphate charging stage the process will automatically time out after 24 hours or you can manually stop this process at any time by pressing and holding down the Select Battery Type Button for 3 seconds Automatic Equalisation Process For Calcium Batteries Only NOTE We recommend to disconnect the Battery from the Vehicle before using this feature Your OzCharge Battery Charger also provides a battery equalisation function What does this feature do Equalisation helps to maintain and balance your battery cells by reversing the high concentration of electrolytes from the bottom of your battery This allows all the cells to charge evenly and makes you get the most out of your battery You can you this feature weekly to ensure your battery is always well maintained Note If you select the Calcium battery type the charger will automatically run the equalisation stage during the charging cycle The Equalisation process does not occur for GEL Sealed WET Battery Type Selection Depending on the charge rate selected this process will time out after 1 to 3 hours Equalising voltage is set to 16 2V for Calcium batteries 4 Disconnecting the Battery charger from Battery a If the Battery is ou
10. r so the levels are halfway between the upper and lower fill lines b Location Ensure the Battery is in a well ventilated area Keep the Charger as far away from Battery as the cables permit Never place the charger directly above the battery being charged as gasses from the Battery will corrode and damage the charger Also keep the charger away from high corrosion wet and moist areas 2 Connecting the Battery charger to you Battery a If the Battery is out of the vehicle 1 Connect the Red lead from the charger to the positive battery terminal 2 Connect the Black lead from the charger to the negative battery terminal b If the Battery is still in the vehicle 1 Determine if the vehicle is positively or negatively earthed i If Negatively Earthed Most Common FIRSTLY Connect the Red battery charger lead to the positive Battery post and then connect the Black battery charger lead to the vehicle s chassis and away from the fuel line ii If Positively Earthed FIRSTLY Connect the Black battery charger lead to the negative battery post and then connect the Red battery charger lead to the vehicle s chassis and away from the fuel line 3 Connect the battery charger to the Mains power 240Vac a The Charger will automatically start when AC power is connected Note If the Fault Indicator LED illuminates Red please check your connections as it s likely that the Positive
11. t of the vehicle 1 Switch OFF and Remove the AC Power Socket from the outlet 2 Remove the Black lead and then the Red lead 3 Check electrolyte levels if possible As they may need topping up with distilled water after charging b If the Battery is in the vehicle 1 Switch OFF and Remove the AC Power Socket from the outlet 2 Remove the lead from the vehicle chassis 3 Remove the lead from the battery 4 Check electrolyte levels if possible As they may need topping up with distilled water after charging CHARGING STAGES REJUVENTATION SOFT START BULK ABSORPTION EQUALISING ANALYSIS FLOAT 1 2 3 4 5 6 7 Mm o Note The Charger automatically stops charging after 24 hours if the Bulk charge cycle is not completed Also if the Battery type selected is Calcium there is an additional equalising stage after the Absorption stage CHARGER SPECIFICATIONS Input 220 260Vac 50Hz Rated output 13 5V at 1 2 4A selectable on OC SW121040 13 5V at 2 4 6A selectable on OC SW121060 3 Type of Lead acid Battery Gel AGM8WET Calcium 4 Charging output voltage Absorption 14 1 14 4 14 7V at Gel Sealed WET Calcium 5 Charging output voltage Automatic Equalisation 16 2V only for Calcium battery 6 Float output voltage 13 8V at Gel Sealed WET Calcium 7 8 9 N Operating Environmental 0 40 degC 90 RH maximum non Condensing Net Weight 630g approx OC SW121040 8 OC SW121060 Dimension L164 x W85 x
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