user instructions & service manual english
Contents
1. FreeCharge is in the closed position with the bolts firmly tightened Connect the jumper cables to the FreeCharge The red cable must be attached to the red positive terminal and the black cable to the black negative terminal of the FreeCharge Figure 6 Ensure that the clamping nuts are securely fastened to prevent the jumper cables from working loose o Connect the FreeCharge s red positive clamp to the positive battery terminal it usually has a red wire connected to it Then attach the black negative clamp to the negative battery terminal o For best results the FreeCharge and the receiving battery should remain connected for several minutes before attempting to crank the engine This allows the FreeCharge to transfer energy to the receiving battery improving cranking performance Crank the engine in 5 second cycles with rests in between as specified above Jump starting with a discharged FreeCharge Battery In the event that the FreeCharge battery is in a state of discharge the step input system may be used to charge the vehicle battery directly To do this follow the procedure below disconnect the FreeCharge internal battery using the battery disconnect switch figure 1 located behind the rubber cover on the outer casing Loosen both bolts and slide the metal switch completely to the left Re tighten the bolts to retain the metal switch in the open position o Switch off the ignition and other power cons2. as the internal spring is attached to this shaft Remove the right outer casing by removing 5 bolts Disconnect the battery as described above Disconnect the 3 alternator wires at the connector block Figure 8 A Remove the left outer casing by removing 5 bolts Remove the gear plate by removing 3 bolts Figure 9 A Remove the secondary gear To gain access to the 4 bolts that fasten the alternator to the left inner casing pull the rotor cup off its base plate figure 9 C Do not lever the rotor cup off but pull in a straight line so as not to cause damage There will be Possible Cause Solution 300 BAT GOL Battery Switch Lead 300 BLS GOL The FreeCharge is totally discharged Recharge the FreeCharge The FreeCharge internal battery is damaged Replace the internal battery The electronic circuitry is damaged Contact the Freeplay Customer Service Center
3. shaft The pedal consists of 2 halves which can be removed once one of the input levers has been removed The input levers and splined drive shaft have an indexing tooth and should only be re assembled in their correct indexed orientation Figure 7 The pedal halves should be assembled with the diamond pattern facing upward 2 Replacing a Stabilizer Arm Figure 7 Remove a stabilizer arm by removing 2 bolts Work the stabilizer arm off the stabilizer pivot shaft and the stabilizer locking shaft DO NOT remove the stabilizer arm pivot shaft figure 8 D from the main assembly if you are not intending to split the 2 inner casings as the internal spring is attached to this shaft Reverse this procedure to re assemble 3 Replacing the Battery Remove the right input lever and right stabilizer arm as described above Remove the right side outer casing by removing its 5 bolts The casing will come away partly as the battery is attached to it The battery should now be visible and its 2 terminals should be accessible Disconnect the wires from the battery by undoing the bolts and remove the battery To insert a new battery reverse the procedure above Ensure that the wires are connected to the correct terminals The red wire to the positive terminal and the black wire to the negative terminal 4 Replacing the Control Panel Remove the battery as described previously Remove the leads to the battery disconnect switch terminals located in
4. ENGLISH Freecharge Weza Portable Energy Source www freeplayenergy com Energy for life USER INSTRUCTIONS amp SERVICE MANUAL 1 INTRODUCTION 2 IMPORTANT SAFETY INFORMATION 3 FEATURES 4 OPERATION 4 1 display and controls 4 2 first time use 4 3 recharging the Freecharge Weza 4 4 operating DC appliances 4 5 jump starting 5 FREECHARGE MAINTENANCE AND STORAGE 5 1 battery care 5 2 battery removal and disposal 6 PRODUCT SPECIFICATIONS 7 CUSTOMER SUPPORT AND WARRANTY 8 FAQ amp TROUBLE SHOOTING 9 SERVICE MANUAL 1 INTRODUCTION Congratulations on purchasing the FreeCharge Weza Portable Energy Source The FreeCharge Weza Portable Energy Source is the only booster pack you will ever need It incorporates failsafe Freeplay technology in the form of a step charge input with both AC and DC recharge capability The FreeCharge provides a truly Portable Energy Source in one compact rugged unit for emergency or recreational use anytime anywhere 2 IMPORTANT SAFETY INFORMATION Read these instructions completely before using the FreeCharge and save them for future reference Read them in conjunction with the user manuals of the particular devices being powered by Freecharge The FreeCharge contains a sealed LEAD ACID battery that must be disposed of properly at the end of its useful life Warning During jump starting the receiving lead acid battery may release explosive gases ensure that it is well venti
5. FreeCharge Q Can charge my 12V DC device while the FreeCharge is being charged either through the DC input or via the Crank A Yes Q What materials are used in the FreeCharge and are they recyclable A The casings are made of polypropylene and glass filled nylon The transmission is made of a combination of acetyl glass filled nylon and aluminum while the input levers pedal and stabilizer arms consist of a glass filled nylon All plastic materials used are thermoplastics and can be recycled The FreeCharge contains a non spill rechargeable Lead Acid battery which needs to be recycled according to regulations stipulated by your local authority Please consult your user manual or contact the Freeplay Customer Support Center for more advice Q How long will a fully charged battery retain its charge A The battery will self discharge at 5 per month when the unit is stored at a temperature of 68 F The self discharge rate increases with an increase in ambient temperature Q Will damage the FreeCharge if crank the pedal too fast A No the faster you crank the more energy you store in the internal battery Q Can over crank the unit does it ever stop you from cranking A No you cannot over crank the internal mechanism It consists of simple gearbox which drives an alternator providing power to the internal battery Q What type of rechargeable battery is used in the FreeCharge A The FreeCharge incorporates a non spil
6. ate of 60 70 steps per minute the FreeCharge will generate approximately 25 40 watts of energy which is stored in the internal battery If the input pedal is used the FreeCharge will immediately display the step input effort indication Once the step input stops the display bar will show the battery level for 5 seconds before powering down Figure 3 AC Source The FreeCharge is supplied with a 18V 1 54 AC DC adapter To charge from the AC DC adapter plug it into a standard AC wall outlet Insert the DC output jack of the adapter into the DC input socket of the FreeCharge figure 4 The display bar lights will illuminate to indicate that the FreeCharge is accepting a charge After approximately 8 hours if the battery is totally discharged the FreeCharge will be fully charged Ensure that the adapter is disconnected from the FreeCharge within 24 hours to prevent over charging When the adapter is disconnected the display bar will show battery level for 5 seconds before powering down Warning Only use the supplied Freeplay AC DC Adapter DC Source Vehicles and boats The FreeCharge is supplied with a DC charging cable that enables charging from the cigarette lighter socket of a vehicle or a boat with a 12 V DC system A meaningful charge level will only be obtained if the vehicle s engine is running while connected to the FreeCharge Plug the one end of the DC charging cable into the FreeCharge s DC input socket figure 4 and the
7. e Belt 107 TB GOL Battery Switch 044 BS GOL Selectable DC Output Adapter not supplied 602 SVDCO GOL PART NAME PART No 200 W S M10 Left Input Lever Left Stabilizer Arm Left Outer Casing Left Rear Foot Left Front Foot Left Inner Casing o The Step Input does not work Symptom The Input arm is either stuck or has no resistance 5 Replacing Gear Components Remove the left input lever and left stabilizer arm as described previously DO NOT remove the stabilizer arm pivot shaft from the main assembly if you are not intending to split the 2 inner casings as the internal spring is attached to this shaft Remove the left outer casing by removing 5 bolts Remove the gear plate by removing 3 bolts Figure 9 A The secondary gear can now be removed or replaced Remove the circlip from the input shaft figure 9 B to remove or replace the input gear Possible Cause Solution Consult the Service manual or contact the Freeplay Customer Service Center Internal gears and mechanism are damaged Secondary Gear Bearing Control Panel Gasket o The display bar does not work Symptom 6 Replacing the Alternator The display bar does not illuminate Remove the right and left input lever and the right and left stabilizer arms as described above DO NOT remove the stabilizer arm pivot shaft from the main assembly if you are not intending to split the 2 inner casings
8. e Weza has been designed for easy maintenance and servicing and is supplied with a service manual and basic tool kit For more information about the FreeCharge Weza Portable Energy Source and other Freeplay products please visit our web site at www freeplayenergy com Warranty Issues Contact the relevant Freeplay Customer Support Center 2 YEAR WARRANTY The manufacturer undertakes that if within 2 two years of purchase this appliance or any part thereof is proved to be defective by reason of faulty workmanship or materials we will at our option repair or replace the same free of charge for labor or materials on condition that o The original invoice or sales receipt indicating the date of purchase product type and dealer s name is presented together with the defective unit The complete unit is returned to the manufacturer or representative postage paid All service work is undertaken by the manufacturer or appointed agents Any defective unit or part shall become the property of the manufacturer This warranty is in addition to your statutory rights 0000 This warranty excludes o Normal wear and tear o Damage through misuse neglect or damage as a result of alteration either internally or externally or damaged from improper use or used in an unsuitable environment o The battery which has a warranty period of 1 year To register your warranty online visit www freeplayenergy com or alternatively fill out and post the s
9. emoval and disposal The battery inside the FreeCharge is a sealed lead acid battery It needs to be removed at the end of its useful life and either recycled or disposed of in accordance with local regulations When the battery needs replacing remove it according to the instructions provided in the FreeCharge Service Manual If you have any questions or problems concerning your unit please contact the Freeplay Customer Support center 6 PRODUCT SPECIFICATIONS Electrical Specifications Battery 12V 7 Amp hours sealed lead acid Cigarette Lighter Output Socket 12V 10 Amps fused self resettable Max DC output power 120 Watts jump start cable length oft 1 6m Cable rating 200 Amps AC DC Charging Adapter 18V 1 5 Amps Full charge time 8 hrs Maximum recommended on charge time 24hrs DC input socket 13V 21V 2 1mm center pin positive Step Input power range 25W 40W Step Input Peak input power 48W General Specifications Dimensions H x W X L 10 4 x 8 6 x 16 3 264 x 218 x 414mm Weight 18 7 Ibs 8 5 kg Warranty 2 years 7 CUSTOMER SUPPORT AND WARRANTY Freeplay Customer Support Center United States and Canada Dixie Sales Tel 1866 6977 529 e mail freeplay dixiesales com United Kingdom Tango Group Tel 0870 6091541 e mail info tangogroup net Rest of the world e mail info freeplayenergy com The Freeplay Customer Support Center provides support to FreeCharge Weza Portable Energy Source owners The FreeCharg
10. gure 8 A Pull away the right inner casing feeding the alternator wires through their conduit and leaving the internal parts assembled in the left inner casing Unhook the spring from the stabilizer arm pivot shaft figure 10 A and pull the drive shaft assembly together with the attached belt and spring free Figure 10 B Remove 2 bolts figure 10 C to detach the belt together with the spring from the drive shaft assembly Reverse this procedure to re assemble making sure that the belt is tracked correctly under the belt retaining bush figure 10 D and over the toothed input pulley figure 10 E before re hooking the spring end to the stabilizer pivot shaft figure 10 A Make sure that the input lever arms are indexed correctly to the drive shaft assembly when re assembling figure 7 PART NAME PART No 114 ILL GOL 012 SL GOL A 002 COL GOL 010 FBL GOL Negative Clamping Nut 008 FFL GOL Gear Plate 001 CIL GOL A 032 PG GOL Secondary Gear PART NAME PART No Stabilizer Locking Shaft 016 SS GOL Serrated Washer Stabilizer Pivot Shaft 016 SS GOL Bolt 200 CS M6x20 Positive Clamping Nut 038 PNG GOL RED Serrated Washer 200 W S M6 038 PNG GOL BLK Washer 200 W M6 005 GP GOL Countersunk Bolt 200 CS C M4x12 144 SGB GOL Circlip 200 CC EX 36 142 SGP GOL A Circlip 200 CC EX 23 Right Inner Casing 003 CIR GOL A Input Gear 140 IGH GOL A Bolt 200 CS M6x10 018 Right Front Foot 009 FFR GOL 110 Alternator 100 ALT GOL 306 Battery 118 _ Driv
11. harge of the FreeCharge s internal battery This will be indicated by the number of lights that are illuminated on the display bar Six lights indicate a fully charged FreeCharge battery After 5 seconds the display bar will return to sleep mode Note Battery level cannot be displayed while the FreeCharge is being charged Input Effort Indication The amount of human energy transferred into the FreeCharge via step input is indicated on the display bar Figure 2 The more vigorous the step input the more energy generated and consequently the more lights will be illuminated When step input stops the display bar will show the battery level for 5 seconds before powering down Charge Indication When receiving an input charge the display bar illuminates in a linear pattern Once the charging source is disconnected the display bar will display the battery level for 5 seconds before powering down 4 2 First Time Use The FreeCharge contains a sealed non spill lead acid battery that should be kept fully charged for efficient and effective use The FreeCharge should be recharged when first received after each use and every 3 months during storage It is recommended that the FreeCharge be fully charged before planning a trip 4 3 Recharging the FreeCharge Step Input To operate fold out the stabilizing arms and place the FreeCharge on a level surface Ensure that you have a firm footing before placing a foot on the input pedal Figure 3 At a r
12. l rechargeable 12 V 7 Amp hour Lead Acid battery Q How long does the warranty last A The FreeCharge has a 2 year warranty Q Can leave my FreeCharge charging from an AC wall charger all the time and unplug it when need to use it A The FreeCharge should not be left on charge for longer than 24 hours Q Should discharge the FreeCharge s internal battery before recharging A No The FreeCharge contains a non spill Lead Acid battery which does not require total discharge before recharging Leaving a Lead Acid battery in a fully discharged state for an extended period of time will cause damage to the battery and limit its life TROUBLESHOOTING o The FreeCharge will not accept a Charge from a DC source Symptom The display bar does not illuminate to show that the FreeCharge is receiving a charge Possible Cause Solution The DC source has insufficient power to charge the FreeCharge or is faulty The FreeCharge will not accept a charge from a DC source that has a voltage lower than 13 volts Disconnect the FreeCharge from the DC source Charge the FreeCharge by using either the Step Input or the AC charging adapter The voltage of the DC source is too high for the FreeCharge over 25 Volts and has burnt out the charge electronic circuitry Replace the control panel unit A faulty charging cable Replace charging cable Incorrect polarity Check polarity o The FreeCharge will not accept a charge from the AC DC adapte
13. lated Always follow the specific instructions in this manual each time you jump start using the FreeCharge General Precautions o When storing the FreeCharge ensure that it is out of reach of children o When connected to the FreeCharge the jumper cable clamps may cause sparks if touched together This could cause damage to the unit Never charge or boost a frozen battery Do not submerge the FreeCharge in water Do not operate in the vicinity of flammables Do not expose the FreeCharge to temperatures over 104F 40C The lead acid battery in the FreeCharge is a sealed unit with no free liquid acid Batteries being jump started with the FreeCharge will likely contain liquid acids which are hazardous if spilled 00000 Precautions when working with batteries Follow manufacturer s instructions and safety procedures Ensure that the area around the battery is well ventilated Never smoke or allow a spark or flame in the vicinity of an engine or batteries Take care not to allow any metal objects to make contact with the positive and negative terminals simultaneously This will short circuit the battery causing sparks and possible damage to the battery or electrical equipment or even cause an explosion o If you need to remove a battery always remove the negative terminal from the battery first o Wear appropriate protective clothing and avoid touching your eyes after working with batteries o If battery acid comes into contact
14. ly to start an engine at 32 F 9 SERVICE MANUAL DISASSEMBLING THE FREECHARGE WEZA Sequence of disassembly Figure 11 NOTE The FreeCharge is supplied with a tool kit to enable disassembly Left and right components these are defined when viewing the FreeCharge from its pedal end The input levers and stabilizer arms must first be removed before the outer and then the inner casings can be opened DO NOT remove the stabilizer arm pivot shaft Figure 8 D from the main assembly if you are not intending to split the 2 inner casings as the internal spring is attached to this shaft Figure 10 A The input levers and splined drive shaft have an indexing tooth which has a rounded tip and should only be assembled in their correct indexed orientation Figure 7 The gearbox and alternator are located under the outer left casing o The battery and bolts to release the control panel assembly are located under the right outer casing The 5 bolts to split the inner casings Figure 8 E are located in the inner right casing battery compartment and are accessed by removing the right outer casing The drive shaft assembly drive belt and return spring are located within the inner casings PART REPLACEMENT 1 Replacing an Input Lever and Pedal Remove the input lever by unscrewing 2 bolts one located at the pivot end of the input lever and the other at the pedal end Work the input lever off the drive shaft and the pedal
15. opposite end into the vehicle s cigarette lighter socket The display bar will illuminate to indicate that the FreeCharge is accepting a charge Disconnect the DC charging cable to terminate the charging process The display bar will then show the battery level for 5 seconds before powering down Solar panels and Wind generators The FreeCharge can be charged from a solar panel or wind generator through the DC input socket Figure 4 The FreeCharge has been designed to accept a DC input voltage of between 13V and 21V Ensure that the input jack from the solar panel or wind generator is the correct size and polarity 2 4mm center pin positive Warning The Solar panel or Wind generator output must be intended for battery charging and have an output of between 13V and 21V DC Refer to the User Manual of the Solar Panel or Wind Generator for detailed instructions on how to recharge batteries freee Figure 4 4 4 Operating DC Appliances The FreeCharge can power many 12 V DC accessories via the cigarette lighter output socket Figure 5 Figure 5 A switchable voltage DC output cable not supplied is available as an accessory enabling the FreeCharge to power a range of DC appliances of up to 12V with a power consumption of up to 0 4 Amperes The FreeCharge is able to deliver a charge or operate an appliance whilst at the same time receive a charge via the DC input charge socket or step input 4 5 Jump starting Warning Alwa
16. r Symptom The display bar does not illuminate after plugging in and switching on the AC DC adapter Possible Cause Solution A faulty AC adapter Check or Replace the AC adapter o The FreeCharge cannot operate or charge an appliance from is cigarette lighter DC output socket Symptom The appliance does not operate Possible Cause Solution The FreeCharge s internal battery is discharged Recharge the FreeCharge using either an AC source DC source or the step input After charging confirm the charge status by pressing the Display Battery Level button The FreeCharge s internal battery is damaged Replace the internal battery o The FreeCharge cannot jump start a boat or vehicle s engine Symptom The engine is not turning over Possible Cause Solution The FreeCharge s battery is not sufficiently Recharge the FreeCharge using an AC or DC charged source After charging confirm the charge status by pressing the Display Battery Level button Alternatively disconnect the FreeCharge s internal battery with the battery disconnect switch and use the step charge input to recharge the receiving battery directly The engine receiving is in poor condition Replace the receiving battery The engine s cranking amps requirements exceeds the FreeCharge s jump start capability It is not possible to jump start this particular engine using FreeCharge Cranking Amps are a measure of how much power a battery can supp
17. the right outer casing Disconnect the 3 alternator wires at the connector block figure 8 A and release the wires from their cleats Remove the 2 bolts that hold the control panel in place figure 8 B The control panel unit can now be pulled free feeding the cables and the 3 alternator wires through the aperture in the right inner casing The control panel is replaced by reversing this procedure Figure 8 Figure 9 considerable resistance due to the alternator magnets Loosen the 4 bolts and remove the alternator drawing its 3 wires from the conduit to the battery compartment Pull the rotor cup off the base plate of the replacement alternator Bolt the base plate to its mountings on the left inner casing Feed the 3 wires through to the battery compartment and reconnect at the connector block in the battery compartment Figure 8 A The order of connection does not matter Replace the rotor cup figure 9 C Replace the other components by reversing the disassembly procedure 7 Replacing the Drive Shaft Assembly or the Drive Belt and Spring Remove the right input lever and right stabiliser arm Remove the right side outer casing by removing its 5 Figure 11 Figure 10 bolts Remove the battery and control panel as described previously Remove the 5 bolts which lock the inner casings figure 8 E and the circlip and washer on the input shaft figure 8 C Disconnect the 3 alternator wires at the connector block fi
18. uming systems and connect the jumper cables as detailed above o Operate the step input pedal at a rate of 60 70 treads per minute for several minutes Larger engines may require in excess of 5 minutes of input effort in order to provide the vehicle battery with enough energy to crank the engine Because you have disconnected the FreeCharge internal battery all the energy you are generating is used to charge the vehicle battery directly o After the engine has started disconnect the black negative clamp and then the red positive clamp from the battery terminals o Finally remove the jumper cables from the FreeCharge ensure the insulated clamping nuts are secured on the terminal posts and restore the battery disconnect switch to the closed position completely to the right with its 2 bolts securely fastened Note It is strongly recommended that you recharge you FreeCharge after use 5 MAINTENANCE AND STORAGE 5 1 Battery Care The FreeCharge contains a sealed Lead Acid battery that should not be stored in a fully discharged state Prolonged storage of a totally discharged Lead Acid battery may damage it Fully recharge the Freecharge before storage The battery self discharge rate is 5 per month when the unit is stored at a temperature of 68 F The self discharge rate increases with an increase in ambient temperature In order to prolong battery life when not in regular use recharge the FreeCharge every 3 months 5 2 Battery r
19. upplied warranty card US amp UK only 6 FAQ amp TROUBLESHOOTING Please read this section before calling the Freeplay Customer Support Center Both the Troubleshooting and FAQ are designed to help you solve the most common problems and answer any questions you may have regarding your FreeCharge Weza FAQ Q Can the FreeCharge s internal battery be replaced A Yes please consult your service manual or contact the Freeplay Customer Support Center for advice Q I have a regular 5 Amp battery charger with crocodile connector clips can use it to charge the FreeCharge through the terminal posts A Yes Q How do I know when the FreeCharge is fully charged A Read all recharging instructions in the user manual The lights on the display bar indicate charge level Q How can test the battery in the FreeCharge to see if it needs to be replaced A The Manufacturer recommends that you use a 100 Amp battery load tester Load the FreeCharge with a 100 Amp load on terminal posts and it should maintain at least 9 V DC Q What products can my FreeCharge power or recharge A most products compatible with a 12V DC power source Q Is using the Step Input the only means to charge my FreeCharge A No The FreeCharge can also be charged from either a DC or AC power source Q How long will it take to charge my FreeCharge from the wall socket with the AC DC charging adapter A It will take approximately 8 hours to fully charge the
20. with skin or clothing wash immediately with soap and water If acid enters your eyes immediately flood them with cold running water and seek immediate medical 0000 attention 3 FEATURES o Step Charge input to provide power anytime anywhere o Step input effort indication o Runs 12 volt DC products via a cigarette lighter socket Sealed non spill 7 amp hour lead acid battery o Jump starting cables designed for safe and efficient use o Internal battery level indicator o Rechargeable at home from a boat motor vehicle or on the move o Service tool kit o AC DC Charging adapter o DC charging cable o The FreeCharge Weza with its accessories and tools is stored neatly in a rugged carry bag Control Panel Battery Disconnect Switch Input Lever Figure 1 Stabilizer Arm Figure 2 control panel XVN ifidNi dilS NIW MIN BATTERY LEVEL MAX FO DISPLAY BATTERY LEVEI Display Bar Battery Level Display Switch 12V DC Output Cigarette Lighter Socket DC OUTPUT 12V 10A fero FreeCharge Weza Portable Energy Source Energy for life DC OUTPUT 12V HIGH CURRENT Negative Jumper Terminal DC Input Socket Positive Jumper Terminal 4 OPERATION 4 1 Display and Controls Battery Level Indication In the default state the FreeCharge battery level indication is in sleep mode to conserve battery power Press the battery level display button figure 2 to display the state of c
21. ys connect the jumper cable clamps positive to positive red clamp to battery positive terminal and negative to negative black clamp to battery negative terminal Never connect in reverse polarity positive to negative as this may cause damage to both the FreeCharge and the battery being jump started Warning The FreeCharge s jump start feature should only be used in 5 second bursts A cranking duration in excess of 5 seconds may cause damage to the FreeCharge battery Ideally the FreeCharge battery should be allowed to recover for at least 2 minutes between jump start cycles Warning Always ensure the insulated clamping nuts are secured on the jump start terminal posts when not in use If a metal object is placed across the terminal posts it may cause a spark or damage the battery Warning Refer to the Precautions When Working With Batteries in the front of this manual oes Figure 6 cCA N Aan Jump starting with a fully charged FreeCharge battery The FreeCharge should ideally be fully charged before attempting to jump start a boat or vehicle engine check the battery level by pressing battery level display button figure 2 If there is insufficient energy recharge the FreeCharge from an AC or DC source Turn the ignition off o Ensure that any other power consuming systems e g lights radio etc are also turned off o Ensure that the Battery Disconnect Switch under the rubber cover on the outer casing of the
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