Gunson G4138 User manual

MULTISTAGE AUTOMATIC
BATTERY CHARGER
INSTRUCTIONS FOR USE
BEFORE COMMENCING CHARGING
Conforms to: BS EN 60335-2-29, BS EN 50081-1, BS EN 50082-1
If you use a battery charger with just the basic features, it may be
adequate for emergency recharging but it may not give full charge or it
may overcharge causing damage.
This charger is a multistage automatic charger with temperature sensor
compensation. It is suitable for all types of lead acid battery, giving long life
and peak performance in summer or winter. It gives the ultimate in
battery care with simplicity of use.
Not suitable for non-rechargeable batteries
• Rapid charging to 100% capacity
• Automatic switching to a gentle standby mode
•Continuous sensing and adjustment of charge condition
• Responsive voltage regulation system
It is therefore ideal for
•Recharging from flat or partial discharge.
•Regular charge / discharge of traction batteries.
• Maintaining a battery in peak condition during storage.
TECHNICAL SPECIFICATIONS
This charger is a multistage automatic charger,suitable for all types of 12 V
lead acid battery. It has a voltage control system with temperature sensor
compensation. This gives continuous sensing and adjustment of charge
conditions to
• Avoid overcharging damage when hot,
• Avoid low charging capacity when cold.
INPUT: 230V 50Hz 100 W. DOUBLE
INSULATED
OUTPUT: 12V 4A DC(5.7A RMS) CONTINUOUS
BATTERY 10Ah TO 60Ah RECOMMENDED
FULL OVERLOAD, REVERSE POLARITY
AND THERMAL CUTOUT PROTECTION
PRODUCT / PARTS MADE IN CHINA
REGULATED VOLTAGES:
14.5V CHARGING 13.8V READY AT 20 DEG. C
TEMPERATURE SENSOR COMPENSATION:
-0.3V PER +10 DEGREES C
CONFORMS TO BS/EN: 60335-2-29, 50081-1, 50082-1
1. PRECAUTIONS
• The battery charger should be stood on a flat, level, non inflammable
surface.Do not obstruct ventilation holes; adrywell ventilated area is
important for correct operation and safety.
• The charger has a safety cut-out which may arc, use only in an area free
from flammable materials and vapours. The charge will become quite
hot when in use,particularly when charging a battery from flat.
• When connecting to or removing connections from the battery, always
ensurethat the ACpower is off at the mains supply in order to prevent
sparking (faulty batteries can emit explosivegasses even with an
automatic charger)
• If charging a battery while connected to any electrical system, make
sure that all electrical loads are switched off. If the battery is fitted to a
vehicle with an engine/charging system see also section 4/5.
• Do not operate the charger for extended periods in an overloaded
state.Ensure the charger is operating within its maximum rated charge
before leaving it unattended. E.g. thermal cut-out not operating on a
frequent basis, (this would give an audible click every few seconds).
Overloading mayinitiallyoccur with a large totallyflat battery and may
also happen with a faulty battery as it draws a continuous very high
current from the charger. Take particular care if a battery has suddenly
discharged for some unknown reason, this may indicate load from an
electrical fault.
• Before disconnecting the battery, check you have codes for audio,
security systems etc or use a Gunson Vehicle Memory Saver to retain
all codes and system settings.
• Battery electrolyte is a corrosive acid. In the event of accidental
contact, rinse repeatedly with plenty of cold water. Always seek medical
attention in cases of eye contact.
• Use only on 12 VOLT LEAD/ACID batteries (includes maintenance free,
gel electrolyte, valve regulated and wet electrolyte types.
See specification paragraph
2. CONNECTIONS
• Make sure the positive (RED) clip is always fitted to the positive (+)
battery connection and the negative (BLACK) clip is fitted to the
negative (-) battery connection
• If the battery is fitted to a vehicle with an engine/charging system –
With the AC power OFF, connect the battery power connection
(usually +) before the GROUND, make the ground connection on the
engine or body away from fuel lines and battery vents. Reverse the
order for disconnection.
• Follow vehicle manufacturers precautions see Section 4)
•ABUZZER IS FITTED FOR INCORRECT CONNECTION WARNING
Note:This buzzer will work even on a battery that appears to be totally
flat but it does actually need a voltage just over 1 volt to operate
Ensure the car is parked safely with the ignition OFF
3. COMMENCING CHARGING
• With AC mains power off, connect the DC output to the battery
(polarity as above)
•Connect to the ACpower supply
•Observe the LED display, the charger should now be charging the
battery, indicated by the illumination of the yellow power output and
the red charging mode lights
IMPORTANT Do not leave the charger unattended if the cut-out
operates and continues to trip regularly (an audible click every few
seconds). This should quicklycease as the batterybegins to charge.
See section 4/5
• When the battery is charged the charging LED will go out, replaced by
the green READYLED. The output LED may then flicker as the charge
level in the battery is being maintained.
•With the READYLED on, the charger can stay connected indefinitely as
the charger will continue to adjust to hold the ideal storage condition
this provides excellent care for a longer life. DO NOT LEAVE A
FAULTY BATTERY CONNECTED TO THE CHARGER
• When the battery is required for use, switch off at the main AC supply
beforedisconnecting the charger from the battery.
4NORMAL CHARGING
•When the charger is initially connected and the AC supply is switched
on, the power output LED and the charging LED should both be ON.
The charger will switch to READYwhen the battery reaches full
charge. The charger will switch almost immediately to READY if the
battery has been recently charged or it will switch within a few minutes
if the batteryhas been standing idle for just a week or two in a fully
charged state.
• If the battery connections are dirty or corroded and do not make a
good contact, the charger may switch to READY mode earlier than
G4138

normal. This may also happen if the connections are disturbed by
movement – disconnect the AC supply then the battery connection and
begin again at section 3.1
• If the battery being charged is fitted to a vehicle with an
engine/charging system it is necessary to observe additional
precautions. Charging the battery on the vehicle can be carried out
safely only if battery connections are clean and tight, the battery is in
reasonable condition and there is no load on the battery (check any
reason for the battery discharging, was an electrical item left on!). This
charger cannot produce SPIKES which are potentially damaging to the
vehicle electronics providing the battery and the connections are good
and charger leads are connected before switching power on.
• A safety cut-out is fitted which operates quickly if the battery takes
excessive current. When the charger is switched on the cut-out may
click a few times if the battery is absolutely flat. DO NOT LEAVE THE
CHARGER UNATTENDED IN THIS CONDITION, CONTINUE TO
OBSERVE THE CHARGER UNTIL THE OVERLOAD SWTICH STOPS
RAPID CLICKING This frequent clicking should not continue for more
than a minute or two followed by occasional clicking for no more that
ten minutes except perhaps with a particularly large battery where the
period may be longer.
• It is normal for the charger to get quite hot when it is charging a
battery from flat. When it switches to READY it will slowly cool until it
is just warm. The battery may also become slightly warm while it is
charging.
• The time taken to fully charge a totally flat battery can be predicted,
but depends on the size of the battery, measured in ampere hours (Ah)
and also on the charger type.This multistage charger is quicker than a
conventional charger.
• A 35Ah battery will fully charge, from flat in around 10 hours and a 40
Ah battery will take around 14 hours. If there is not enough time to
fullycharge the batteryit may be used before the READY light is on.
The battery power may be close to normal but duration of output
without a further charge will be reduced. The battery should be fully
charged as soon as possible as this ensures longer battery life.
IF THE BATTERY DOES NOT CHARGE NORMALLY OR IT’S
PERFORMANCE IS POOR PLEASE READ THE FOLLOWING
SECTIONS
5 SIGNS AND SYMPTOMS
•The safety cut-out should onlyoperate in the early stages of charging a
flat battery. It guards against high batterycurrent and against the
battery charger overheating. Do not attempt to charge a battery which
continues to cause excessive cut-out operation.
• A battery that appears to charge quickly from flat may have a reduced
capacity die to age.The battery may have been damaged by leaving it
flat for too long. This could give poor performance in use or problems
while charging.
•Take care if the battery connections are poor or the battery is resisting
acharge due to a fault or leaving the battery flat for too long. You may
damage a car’selectrical system if you jump or bump startthe engine
without first getting the battery to take a charge.
• A battery in good condition should not suffer from gassing at any time
while using this charger.This protection is just one of the advanced
features of the charger. (Gassing is the rapid formation of small bubbles
and can be detected by listening carefully to the battery). If the battery
has a faulty cell, gassing may occur in that cell or in all of the other cells
if the fault is a short circuit. (It will then behave like a 10volt battery
with a 12 volt charger)
• Do not continue to use a battery that gasses, becomes very warm
towards the end of the charging or does not show a READY light after
afull charge. The battery has little life remaining and should be
replaced.
NOTE: Keep your new battery well charged to prolong its life. If it has
to work extra hard on occasions give it an additional top up charge as
soon as it’s convenient.
• A battery should preferably be charged until it reaches full charge, since
abattery left in a partially charges state will slowly deteriorate.
6 TESTING THE BATTERY
• If a fault is suspected, check the following descriptions, the performance
can best be checked with a Volt Meter or Multimeter
NOTE: All the stated values for voltage on charge are approximate
(within 0.5 volts) as the sensor system will adjust according to the
charging conditions.
The following normal battery voltages are a useful guide
(A 12 volt battery will not usually measure 12.0 volts)
•Battery on CHARGING up to 14.5 volts
• Battery on READY 13.8 volts
• Battery just taken off charge 13.4 volts (at full charge)
This includes a SURFACE charge which can be removed by loading the
battery (headlights on for 1 min) or allowing the battery to stand idle
for 24hrs giving 12.8 volts.
•Abatterywith one cell completely defective will settle to a lower
voltage (10.5 volts)
• Battery half charged 12.4 volts or almost flat (12.0 volts).An old battery
maybe around 0.5 volt lower on all readings.
With the charger connected to the AC supply and no battery
connected – the CHARGING mode light should be ON.
Ameasurement of voltage at the output leads will give a reading of
approximately 11 volts if the charger is operating correctly
With the charger connected to the AC supply and a battery connected
the POWER OUTPUT and CHARGING LED lights should be on
brightlywhen in CHARGING mode
• The output voltage, measured at the battery terminals, will depend on
the load. It should read between 14.5 volts and 12 volts (at rated full
load). At even higher loads the output voltage will be lower and may
even switch between different values if the output is operation
In READY mode the power OUTPUT LED may flicker, the READY LED
should be bright.
•The voltage should stabilise at 13.8 volts. If the OUTPUT LED is on full
there may be an external load on the battery or an internal battery
fault.
It is not possible to test the charger using a 12volt tester bulb as the
protection system detects an incorrect load. (I.e. it does not recognise if
as a battery of the correct polarity). Check the charger on a good
battery
WARRANTY
This warranty is in addition to the statutory rights of the purchaser.
The Tool Connection has made every effort to ensure that this product is
of the highest quality.
If this product should require service or repair at any time, it should be
returned to:
The Tool Connection Limited,
Kineton Road Industrial Estate,
Southam,
Warwickshire,
CV47 0DR
Technical Services Department: ++44 (0) 1926 818181
If returning goods for service or for any other reason please include full
details and a description of the faults.
When goods are returned for service or repair, full details of faults requiring
attention should be given, and also date of purchase.