6/12/24 volt automatic/manual workshop battery charger
Contents
1. of overcharging Once the battery is full the battery charger will automatically start to maintain the battery The charger monitors the battery voltage and continues to top up the battery keeping it fully charged and ready for use Manual Charging The charger in this mode will continue to charge the battery until the timer finishes or is turned off and requires the user to monitor the charging battery When used by experienced users it can deliver an equalization charge to balance the voltage in the battery s cells LED Indication OVERLOAD Red LED Flashing The LED will flash when the transformer or the current regulators SCR s have got too hot POWER ON Red LED ON The LED comes on when connected to power and the charger is switched on POWER ON Red LED Flashing Indicates that the battery clamps have been connected in reverse polarity Charging Orange LED on The LED comes on indicating charging Fully charged Green LED on The LED comes on when the battery is charged VOLT Red LED ON The LED indicates that Voltage is being displayed AMP Red LED ON The LED indicates that Amps or current is being displayed LED Voltage Amp Display The charger has a VOLT and AMP meter built in When the charger is initially powered up the display will show voltage When the VOLT AMP button is pressed the Amps will be displayed press the button again the display will go back to Volts When Volts is displayed this indicates the state of c2. LLY CHARGED LED to illuminate STEP 8 SET CHARGE CONTROL to MANUAL STEP 9 SET DISPLAY TO READ VOLTAGE STEP 10 CHECK THE BATTERY Set the POWER TIMER to 2 hours and check the battery every 30 minutes to ensure it does not get too warm and the batteries electrolyte is not bubbling profusely You may need to may need to reset the timer after 2 hours STEP 10A CHARGING 6 VOLT BATTERIES Wait for the voltage to reach 8 0 Volts and then turn the charger off STEP 10B CHARGING 12 VOLT BATTERIES Wait for the voltage to reach 16 0 Volts and then turn the charger off STEP 11 DISCONNECT THE CHARGER FROM THE BATTERY a Ensure the battery charger is off and is disconnected from the 240V supply b Remove the leads from the battery C Check the electrolyte if possible The electrolyte may need to be topped up after charging FREQUENTLY ASKED QUESTIONS How do I know if the battery is charged The battery charger s GREEN FULLY CHARGED LED will illuminate to indicate when the battery is fully charged Alternatively use a Battery Hydrometer Projecta Part No BH100 A reading of 1 250 or more in each cell indicates a fully charged battery Why does the battery charger have two ratings Battery chargers for automotive use have traditionally been given an RMS rating in the past This rating is now used as an industry reference only Australian Standards now require all battery chargers to be rated at the charger s co
3. PR JECTA 6 12 24 VOLT AUTOMATIC MANUAL WORKSHOP BATTERY CHARGER PR JECTA WORKSHOP 1200 P No s HDBC20 HDBC35 WARNING Explosive gases Prevent flames and sparks Provide adequate ventilation during charging Before charging read the instructions For indoor use Do not expose to rain For charging lead acid batteries ONLY of the size amp voltage specified in the specifications table Always charge the battery on the correct voltage setting Never set the charger to a higher voltage than the battery Disconnect the 240V mains supply before making or breaking the connections to the battery Do not attempt to charge non rechargeable batteries Never charge a frozen battery This appliance is not intended for use by young children or infirm persons unless they have been adequately supervised by a responsible person to ensure that they can use the appliance safely Young children should be supervised to ensure that they do not play with the appliance Charge the battery in a suitable area as the battery may give off corrosive fumes which could damage delicate surfaces Ensure all vehicle accessories and lights are turned off prior to charging If the AC cord is damaged it must be returned to an authorized Service Center FEATURES Automatic Charging When in automatic mode the charger will stop charging the battery when the battery is fully charged You can leave the charger connected to the battery without risk
4. Size 301x264x161mm 301x264x161mm Weight 8 6kg 11 5kg CHARGING amp ENGINE START INSTRUCTIONS STEP 1 CHECK THE ELECTROLYTE LEVEL Prior to charging the battery remove the vent caps and check the electrolyte level Not required on sealed amp maintenance free batteries The electrolyte should be 6mm 1 4 above the battery s plates If low top up the electrolyte with distilled water to the correct level and refit the vent caps STEP 2A CONNECTION OUT OF VEHICLE Connect the RED lead battery clip from the charger to the Positive battery post Connect the BLACK lead battery clip from the charger to the Negative battery post CONNECTION OUT OF VEHICLE m PR JECTA STEP 2B CONNECTION IN VEHICLE Determine if the vehicle is Positively or Negatively earthed Negatively earthed vehicles have a cable usually black from the Negative battery terminal to the vehicle s chassis Negatively earthed Most Vehicles Connect the RED lead battery clip from the charger to the Positive battery terminal Connect the BLACK lead battery clip from the charger to the vehicle s chassis away from the fuel line or moving parts CONNECTION IN VEHICLE NEGATIVELY EARTHED Positively earthed Connect the BLACK lead battery clip from the charger to the Negative battery terminal Connect the RED lead battery clip from the charger to the vehicle s ch
5. assis away from the fuel line or moving parts CONNECTION IN VEHICLE POSITIVELY EARTHED STEP 3 CONNECT TO 240V MAINS POWER Connect the battery charger to the 240V mains power ensure the battery charger POWER ON OFF TIMER is set to the OFF position STEP 4 SET BATTERY VOLTAGE Set BATTERY VOLTAGE switch to either 6V 12V or 24V STEP 5 SET CHARGE CONTROL AUTO It is recommended to run AUTO mode when the battery is in the vehicle MANUAL In this mode the charger continues to operate and may in time overcharge and damage the battery It is recommended to use the timer with this mode ENGINE START Use this mode to provide a rapid charge Constant Supervision is recommended TS EN POWER ON OFF TIMER CHARGE CONTROL BATTERY VOLTAGE STEP 6 SET the POWER ON OFF TIMER switch ON The charger will remain on It is recommended using in AUTOMATIC mode TIMER Can be used in any charging mode STEP 7A CHARGING The POWER and CHARGING LED s will illuminate When the FULLY CHARGED LED illuminates charging is complete Manual mode Note Charging will continue until the timer finishes or the power is turned off to the charger The battery needs to be monitored to ensure is does not overcharge STEP 7B ENGINE START Allow the charger to boost charge the battery for 5 minutes b Turn the cars ignition key to start the engine If engine fails to start after 3 seconds wait 5 minutes before
6. attempting to start the engine again NOTE Do not repeat this operation more than 5 times STEP 8 DISCONNECTION Ensure the power selection switch is set to the OFF position and disconnect from the 240V supply Battery out of vehicle Remove the BLACK lead battery clip from the battery Remove the RED lead battery clip from the battery Battery in vehicle Remove the chassis connection Remove the battery terminal connection CALCIUM BATTERY CHARGING OR EQUALIZATION CHARGE Calcium batteries are becoming more commonly sold as they have a longer shelf life 4 times longer than a lead antimony battery they also have a better ability to withstand higher engine bay temperatures and have increased cranking output They also require a different charging technique when left flat or when deeply discharged STEP 1 to 3 Follow STEPS 1 to 3 of the Charging instructions of this booklet Ensure that the battery is removed from the vehicle to prevent the batteries electrolyte from spilling over and damaging the car or engine bay STEP 4 SET BATTERY VOLTAGE Set switch to either 6V or 12V depending on what battery voltage you are charging For 24V vehicles the batteries should be disconnected and the two 12Volt batteries need to be charged separately eem SX a 10 9 POWER ON OFF TIMER CHARGE CONTROL BATTERY VOLTAGE STEP 5 SET CHARGE CONTROL TO AUTO STEP 6 SET the POWER ON OFF TIMER switch to ON STEP 7 WAIT for the FU
7. batteries can be flattened to the point where they have very little or no Voltage This can occur if a small amount of power is used for a long time for example a map reading light is left on for a week or more Projecta automatic chargers are designed to charge from as little as 3 Volts If the voltage is lower than 3 0V press the override button to start the charger 11 12 Can use the charger as a power supply Projecta automatic chargers are designed to only supply power to the battery clips when they are correctly connected to a battery this is to prevent sparks or damage to the charger or battery if connected incorrectly by mistake This safety feature prevents the charger from being used as a Power Supply No Voltage will be present at the clips In maintenance mode why does the current go high then low again While in maintenance mode it is normal for the current to go high and then low The charger is maintaining the battery voltage between the Cut In and Cut Out voltages The pulses of power are topping up the battery to maintain it fully charged TYPICAL BATTERY CHARGER OUTPUT DURING CHARGING CURRENT AMPS CHARGING FULLY CHARGED TIME HOURS k sje gt Q What are Volts and Amps VOLTS The term voltage refers to the electrical force or electric potential to do work between two terminals or a good analogy is water pressure in a pipe For example a battery has 12 Volts between the positive and ne
8. ed incorrectly the charger will flash the power LED and not charge the battery Short circuit protection There is no voltage at the leads until the battery clamps are connected to the battery Overload protection To prevent damage to the electronics the charger will switch off when overloaded it will automatically reset when safe The overload LED will flash in these times ns E GE PR JECTA WORKSHOP 1200 cnim 6 12 24 VOLT 12 AMP AUTOMATIC BATTERY CHARGER WITH ENGINE START vor POWER u ee AMP CHARGING CHARGING VOLT AMP OVERRIDE VOLTAGE CURRENT FULLY CHARGED MER Oy gt 2 19 POWER ON OFF TIMER CHARGE CONTROL BATTERY VOLTAGE Image of HDBC20 HDBC35 not shown SPECIFICATIONS PART NO HDBC20 HDBC35 Type Manual and Automatic Manual and Automatic Input 240VAC 50HZ 240VAC 50HZ Input power 1 35A 324W 2 65A 636W Output Voltage Nominal 6VDC 12VDC 24VDC 6VDC 12VDC 24VDC Output Current 12A 6VDC 21A O 6VDC Continuous 12A 12VDC 21A 12 5VDC 7 74 26VDC 13 5A 26VDC Suitable for charging 6V 12V 24V lead acid batteries Battery Range CCA 450 1200 550 2000 MCA 600 1400 700 2500 Ah 65 160 75 250 Minium Start Voltage OV 0v Charge control Cut Out 6V 71V 71V 12V 14 2V 14 2V 24V 28 4V 28 4V Cut In 6V 6 7V 6 7V 12V 13 4V 13 4V 24V 26 8V 26 8V Output lead specifications 6mm cable 6mm cable 183cm 183cm
9. gative terminals or a 6 Volt battery has 6 Volts between the positive and negative terminals AMPS The term AMPS is the unit of measure used for current Which can be described as the flow of electric charge in a circuit Again if you use the water analogy this would refer to how much water is flowing through the pipe For example if the current is reading 12 Amps then this is the amount of energy going into the battery How does a typical battery charge A typical flat battery has a low internal resistance when first connected to a charger the battery will accept a high current As the battery slowly charges the voltage and internal resistance will rise causing the battery to accept less and less current TYPICAL BATTERY CHARGER OUTPUT DURING CHARGING VOLTS AMPS CHARGING FULLY CHARGED pj ME HOURS 13 NOTES 15 Distributed by AUSTRALIAN OFFICE Brown amp Watson International Pty Ltd Knoxfield Victoria 3180 Telephone 03 9730 6000 Facsimile 03 9730 6050 National Toll Free 1800 113 443 NEW ZEALAND OFFICE Narva New Zealand Ltd 22 24 Olive Road PO Box 12556 Penrose Auckland New Zealand Telephone 09 525 4575 Facsimile 09 579 1192 15151 Issue 1 18 3 11
10. harge of the battery when Amps is displayed this indicates how much charge is being accepted by the battery Override Button The battery charger measures the battery voltage at the clamps to determine if the battery is correctly connected A reading above 3V will activate the battery charger In some instances where the battery is extremely flat it is possible to have correct connection and the battery to be below the 3V limit In this instance check the battery leads to ensure they are connected correctly and press the OVERRIDE button to activate the battery charger Multi Voltage Suitable for charging 6V 12V amp 24V batteries Engine Start If you need to get going and the battery is flat then the engine start will help you out Connect the charger to the battery set it to engine start mode for 5 minutes then start your engine 0 14 Hour timer Automatically turns the battery charger off after a set time The timer has 1 hour intervals with a maximum of 14 hours This switch can also be set to permanently ON Toroidal Transformer Using the latest technology in transformer design toroidal transformers don t use a solid iron core like traditional transformers making them lighter and more compact They deliver more power than a traditional transformer charger of the same size Protection features The charger is fitted with the following protection features Reverse polarity protection Where the battery leads are connect
11. ntinuous output at a nominated voltage we express this as mA milliamps rather than A Amps to avoid confusion Why does the FULLY CHARGED LED come on straight away There are four possible reasons why the FULLY CHARGED LED may come on straight away 1 The battery is fully charged 2 The battery has taken a surface charge 3 The battery has a faulty cell 4 The BATTERY VOLTAGE setting on the charger is set lower than the battery voltage What is Surface Charge Batteries unused or left flat for some time build up a resistance to being recharged When the charger is first connected these batteries will take a surface charge and the FULLY CHARGED LED will illuminate within a short while The battery however is not fully charged the charger is voltage sensitive and cannot differentiate between a surface charge and a fully charged battery After a few hours the battery may start to accept some charge but most batteries with this condition will not recover What is a Faulty Cell 12 Volt batteries contain 6 cells and one faulty cell is enough to ruin your battery If after eight hours of charging your battery is still flat you should test the cells using a hydrometer If one reading is lower than the rest it indicates a faulty cell It is pointless to continue charging as the battery needs replacing have connected the charger properly but the Orange charging light does not come on In some cases
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