KICK ASS KACHG1222 User manual

12V 22 AMP
9 STAGE AUTOMATIC
BATTERY CHARGER
USER MANUAL
KACHG1222
V1.4

TABLE OF CONTENTS
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1.0 Welcome and Safety1.0 Welcome and Safety
1.1 Flammable Gases and Fumes 1.1 Flammable Gases and Fumes
1.2 Operational Safety Instructions 1.2 Operational Safety Instructions
1.3 DIY Repair & Modifications 1.3 DIY Repair & Modifications
1.4 Supported Battery Types 1.4 Supported Battery Types
1.5 Precautions When Working With Batteries 1.5 Precautions When Working With Batteries
1.6 Verifying Suitability of Batteries 1.6 Verifying Suitability of Batteries
1.7 Protection Features 1.7 Protection Features
2.0 What's Included2.0 What's Included
3.0 Installation and Mounting3.0 Installation and Mounting
4.0 Product Overview4.0 Product Overview
4.1 Charger features 4.1 Charger features
4.2 LCD Display 4.2 LCD Display
4.3 Indicator LEDs 4.3 Indicator LEDs
4.4 Supported Rechargeable Batteries 4.4 Supported Rechargeable Batteries
5.0 Standard Charging Modes and Operation5.0 Standard Charging Modes and Operation
5.1 Standard Charging Modes 5.1 Standard Charging Modes
5.2 Standard Operation 5.2 Standard Operation
6.0 Special Modes and Operation6.0 Special Modes and Operation
6.1 Lithium Activation Mode 6.1 Lithium Activation Mode
6.2 Quiet Night Mode 6.2 Quiet Night Mode
6.3 Recondition Mode 6.3 Recondition Mode
7.0 Battery Type & Capacity7.0 Battery Type & Capacity
8.0 Charging Profile8.0 Charging Profile
12V Standard / Gel / AGM Batteries 12V Standard / Gel / AGM Batteries
12V LifePo4 Batteries 12V LifePo4 Batteries
9.0 Charger Error Codes9.0 Charger Error Codes
10.0 Specifications10.0 Specifications
1.0 Welcome and Safety
1.1 Flammable Gases and Fumes
1.2 Operational Safety Instructions
1.3 DIY Repair & Modifications
1.4 Supported Battery Types
1.5 Precautions When Working With Batteries
1.6 Verifying Suitability of Batteries
1.7 Protection Features
2.0 What's Included
3.0 Installation and Mounting
4.0 Product Overview
4.1 Charger features
4.2 LCD Display
4.3 Indicator LEDs
4.4 Supported Rechargeable Batteries
5.0 Standard Charging Modes and Operation
5.1 Standard Charging Modes
5.2 Standard Operation
6.0 Special Modes and Operation
6.1 Lithium Activation Mode
6.2 Quiet Night Mode
6.3 Recondition Mode
7.0 Battery Type & Capacity
8.0 Charging Profile
12V Standard / Gel / AGM Batteries
12V LifePo4 Batteries
9.0 Charger Error Codes
10.0 Specifications

1
1.0 Welcome and Safety
Thank you for purchasing a KickAss 12 Volt 22 Amp Smart Charger. This charger is
controlled by a microprocessor with 9-stage charging characteristics for charging your
batteries to their optimum. Please ensure you have read and understood all of the
instructions, recommendations and warnings in this manual before operating the battery
charger. Please also ensure that the battery charger is set up as illustrated in the
installation instructions.
1.1 Flammable Gases and Fumes
Keep Away
From Sparks
Keep Away From
Open Flames
Operate On Well
Ventilated Area
Battery Releases
Flammable Gas
Charging Lead-Acid batteries can result in gases being released from the battery. The gases
are flammable and care should be taken to ensure that there are no naked flames or sparks
around the battery. The storage area of batteries should also be well ventilated during normal
operation as well as during charging.
1.2 Operational Safety Instructions
Please follow the following operational safety instructions for the charger:
lThe charger is designed for charging 12V batteries only.
lThe charger is designed for indoor use only.
lDo not expose the charger to rain, moisture, sand or excessive dust.
lDo not place the charger so that dust, dirt or similar can be sucked in by the cooling fan.
lWhen not in use, store the charger in a dry area and avoid exposure to moisture.
lConnection to mains supply is to be in accordance with National wiring rules.
lDisconnect the 240V AC mains supply before making or breaking
lthe connections to the battery.
lCorrosive substances may escape from the battery during charging and damage
delicate surfaces. Store and charge in a suitable area.
lDo not touch the battery clamps together when the charger is on.
lDo not operate a charger if it has been exposed to a hard impact, been dropped or
otherwise damaged.
lEnsure the charger power cord is positioned so as to prevent it from being stepped on,
tripped over or damaged.
lDo not pull out the plug by the cord when unplugging the charger. Pulling on the cord may
cause damage to the cord or the plug.
lDo not cover the charger while charging, and make sure that the air inlet and outlet vents
are not obstructed.

2
lDo not leave the charger unattended for long periods of time.
lEnsure vehicle engine, ignition and accessories including lights, appliances etc are
turned off prior to charging.
lThis appliance is not intended for use by young children or any person with
llimited capabilities (mental and physical) unless they have been adequately
lsupervised by a responsible person to ensure that they can use the appliance safely.
Indoor Use
Only
No Excessive
Dust
No Excessive
Moisture
1.3 DIY Repair & Modifications
The charger should not be opened, and any attempt at modification or repair without the
consent of Kickass will void any warranty. Please refer to the back of this manual for warranty
details. If the AC cord is damaged do not attempt to use the charger and do not attempt to
repair by yourself. It must either be replaced or repaired by an authorized professional, as
approved by Kickass.
1.4 Supported Battery Types
This charger is only suitable for charging the following 12V battery types:
Lead Acid / GEL AGM Lithium
(LiFePO4)
This charger should not be used to recharge NICAD or any other type of battery that has not
been listed in this section.
1.5 Precautions When Working With Batteries
lDo not attempt to charge non-rechargeable batteries.
lDo not attempt to charge frozen batteries.
lDo not attempt to charge a battery that is damaged or seems to be damaged.
lDo not attempt to charge a lithium battery at temperatures below 0°C (32°F).
lDo not attempt to charge a lithium battery that does not have an in built Battery
Management System (BMS).
lDo not charge batteries smaller than 15Ah or larger than 300Ah.
lDo not smoke or allow a spark or flame in the vicinity of the battery or engine.
For 12V Rechargeable
Batteries Only
12V

3
lDo not drop a metal tool on the battery, as it could result in a short circuit and a possible
explosion.
lDo not place the charger on top of the battery while charging.
lAvoid getting electrolyte on your skin or clothes. It is extremely corrosive and can cause
burns.
lIf electrolyte gets into your eyes - wash immediately with water and seek medical
attention immediately.
IMPORTANT: This charger has only been designed for charging the batteries as outlined in
this manual. Always ensure to refer back to the technical specifications of the battery that you
have. Do not use this charger for any purpose other than what has been specified in this
manual.
1.6 Verifying Suitability of Batteries
lAlways confirm battery manufacturer safety recommendations and technical
specifications before charging the batteries with a charger.
lEach battery has a recommended maximum charge voltage. Ensure that the charge
voltage of the mode you have selected, does not exceed the battery manufacturers
recommendations.
lEach battery has a recommended continuous current rating. Make sure that the charger
does not exceed the battery manufacturers recommended maximum charging current.
1.7 Protection Features
Polarity Protection
This unit offers reverse-polarity protection, the RED LED will blink and the charging process
will not start. If this happens, unplug immediately from mains, connect the red clamp to
positive (+) battery post, and black clamp to negative (-) post, then plug into the mains power
and the charging process will start.
Short-circuit protection
Should you accidentally touch the clamps together whilst the mains power is on, the charger
will automatically shut down. If this happens, unplug from mains, disconnect and start the
operation process again being careful not to touch the clamps together.
Over Temperature Protection
The charger will reduce the charge current to 2A if the internal temperature reaches 95
degrees celsius protecting both charger and battery.
Charge Memory
If the mains AC connection is disconnected for any reason during the charging process, the
charger will remember its previous charge settings and will automatically start charging in
the same mode once mains AC power is restored, providing the battery clamps have not
been disconnected.

4
2.0 What's Included
POWER
CHARGING/
FAULT
22A
SMART
CHARGER
C O M PAT I B I L I T Y
LEAD ACID GEL AGM LITHIUM
124V
AUTO
FULL
9 18 7 6 5 4 3 2
VV
A
%
RECON
12V 22 AMP
9 STAGE AUTOMATIC
BATTERY CHARGER
USER MANUAL
KACHG1222
1 x KickAss 12V 22Amp
smart battery charger
1 x Anderson to alligator
adapter lead
1 x User guide
3.0 Installation and Mounting
1. This charger works with Australian 240V AC mains power outlets and is designed to be
used indoors out of areas of excessive dust or moisture.
2. The charger can be used on a flat surface if not mounted or mounted following the
instructions below.
3. For caravan and camper installations please ensure all AC and DC wiring complies to the
appropriate standards before mounting and installing this charger.
4. Never mount or use this charger on or in close proximity to the batteries.
5. Mounting points - the charger has two mounting point options, permanent and temporary.
MOUNTING HOOK
A. Permanent Mounting
Use the 4 mounting points and secure
with bolts or screws. This mounting is
recommended for caravan, camper or
in-vehicle set ups.
B. Temporary Mounting
Use the mounting hook that can be
swung out from the rear of the charger.
The hook can be mounted on a suitable
and secure holding retainer such as a
screw or hanger.
MOUNTING POINT
6mm Mounting Hole
MOUNTING POINT
6mm Mounting Hole

5
Charger Fan Intake Clearance
Please ensure there is adequate air clearance from both the cooling inlet and outlet for the
charger to operate correctly.
124V
AUTO
FULL
9 18 7 6 5 4 3 2
VV
A
%
RECON
4.0 Product Overview
4.1 Charger Features
POWER
CHARGING/
FAULT
22A
SMART
CHARGER
C O M PA T I B I L I T Y
LEAD ACID GEL AGM LITHIUM
124V
AUTO
FULL
9 18 7 6 5 4 3 2
VV
A
%
RECON
Power LED
Mode Button
Status LED
LCD Display
AUTO
RECON
FULL
9 18 7 6 5 4 3 2
VV
A
%
4.2 LCD Display

6
Battery Reverse Polarity
Connection Indicator
Wrong Battery Type/
Charging Fail
Battery Voltage Level
Indicator
Digital Voltage Display
Slow STD Mode
V
Fast STD Mode
Fast AGM Mode
AGM Recon Mode
Slow Lithium Mode
Fast Lithium Mode
RECON
4.3 Indicator LEDs
Power LED
When the Power LED
is Green, it indicates
the connection of
power to the charger.
Status LED
When the Status LED
is Green, it indicates
that the battery is fully
charged.
When the Status LED
is blinking Green, it
indicates that the
battery is charging.
When the Status LED
is Red, it indicates
that there is a
charging failure, a
battery problem or
reverse polarity
scenario.
4.4 Supported Rechargeable Batteries
AGM (Absorbed Glass Matt)
GEL
SLA & FLA (Sealed & Flooded Lead Acid)
LiFePO4 (Lithium Iron Phosphate)
The battery types that our charger supports include:
Note 1: The STD Mode in the charger caters for GEL and Lead Acid Batteries.
Note 2: The AGM Mode in the charger caters for AGM Batteries.
Note 3: The Li Mode in the charger caters for LiFePO4 Batteries.

7
5.0 Standard Charging Modes and Operation
5.1 Standard Charging Modes
The Mode button is used to select the different battery charger modes as shown below. The
mode should be selected within 10 seconds of connecting the AC mains before the charger
starts charging.
Slow STD Mode
Slow charge with 12V sealed or flooded lead acid or
GEL battery, MAX 4A.
Fast STD Mode
Fast charge with 12V sealed or flooded lead acid or
GEL battery, Max 22A.
Fast AGM Mode
Fast charge with 12V AGM type lead acid battery,
Max 22A.
AGM Recon Mode
This reconditioning mode is for batteries that havent
been used for a long period of time or have gone
through a deep discharge which may have degraded
the battery performance. This mode is only for 12V
AGM batteries with 22A Max charge current capacity.
Caution: Recondition mode may decrease the battery
life so consult your battery vendor for advice if
necessary when using this mode
Slow Lithium
Slow charge with 12V LiFePO4 battery, Max 7A.
Fast Lithium
Fast charge with 12V LiFePO4 battery, Max 22A.

8
5.2 Standard Operation
To connect the charger to the battery and begin the charging process, please ensure the
following procedure is followed.
BATTERY
Ensure that the 240V AC Mains is disconnected.
STEP
1
When connecting using the alligator clamps, ensure it is connected via the anderson
connector to the charger. Then Connect the POSTIVE + (Red) clamp of the charger to
the POSITIVE + terminal on the battery post and the NEGATIVE - (black) clamp of the
charger to the NEGATIVE - terminal on the battery post.
STEP
2A
BATTERY
When connecting directly by the anderson connector, plug it into the mating anderson
connector charge port of a battery box or other device with anderson charging input
ensuring correct polarity.
STEP
2B
BATTERY BOX

9
Plug in the 240V AC mains plug and switch on at the wall, the charger's display will then
operate and show the battery voltage. Illustration voltage for reference only.
STEP
3
BATTERY
Select the appropriate charge mode as described above ensuing it is correct for the battery
type connected. The charge mode should be selected within 10 seconds of connecting the
240V AC power.
STEP
4
After 10 seconds, the charger
will begin charging, the green
status light should flash and
the appropriate charge stage
will display in the LCD.
STEP
5Once the charge process has completed the green
status light will remain solid on and the LCD will display
full as below.
STEP
6
POWER
CHARGING/
FAULT
22A
SMART
CHARGER
C O M PA T I B I L I T Y
LEAD ACID GEL AGM LITHIUM
FAST AGM MODE
AGM RECON MODE
SLOW LITHIUM MODE
FAST STD MODE
SLOW STD MODE
FAST LITHIUM MODE

10
If the battery needs to be disconnected, the safest way to do so is to ensure that the 240V AC
mains is disconnected before removing the alligator clamps or Anderson connection to the
battery. This will avoid any undesirable sparks from forming.
NOTE: Disconnecting the alligator clips from the battery while the charger is powered, may
create sparks.
STEP
7
BATTERY
12 V
12
V
x
BATTERY

11
6.0 Special Modes and Operation
6.1 Lithium Activation Mode
All Lithium batteries have a Battery Management System (BMS) built into the battery packs
to protect them from unsafe operating conditions. One of these conditions is Under Voltage
Protection, which occurs when the batteries are depleted below a certain voltage. When a
battery pack reaches this protection mode the BMS does not allow the battery to be
discharged any further in order to protect the cells from being damaged. Some BMS's, while
in this protection mode, may disconnect the external battery terminals from the internal cells.
This can create problems for some chargers, because they expect to see a voltage at the
battery terminals, before they can start charging.
Our Lithium Battery Activation Mode lets our charger know that the battery being charged is
in this Under Voltage Protection Mode.
To activate Lithium Battery Activation Mode do the following:
Connect the alligator
clips to the battery in
protection mode
STEP
1
LITHIUM
BATTERY
Plug the charger into a 240V AC power point.
STEP
2
240V AC
Select Lithium Mode. (within 10 seconds of powering up the charger)
STEP
3
240V AC

12
Press and hold the Mode button for more than 4 seconds. The charger will enter Lithium
Activation mode.
STEP
4
LITHIUM
BATTERY
240V AC
In this mode, the output voltage will be a constant 13.9V supplying 22A. On the display
screen AUTO will be on and the Battery Icon on the left hand side will be blinking. The
charger will stay in Lithium Activation Mode for 10 minutes, after which time the charger will
have reactivated the BMS to allow normal charging of the battery.
NOTE: Lithium Activation Mode is not accessible while in AGM or STD charging modes.
NOTE: The charger can exit this mode prior to the 10 minute time limit, by pressing the Mode
button for 4 seconds again.
NOTE: Some batteries do have a voltage on the terminals in Under Voltage Protection
mode, in which case this Activation Mode will not be required.

13
6.2 Quiet Night Mode
When charging a battery at high current, the charger fan turns on to cool the unit down. This
can at times be undesirable, especially when trying to get some sleep at your campsite.
While charging a battery (after pre-charging period), holding the mode button for 4 seconds
will make the charger go into Quiet Night Mode, which lowers the output current to 5A, and at
the same time turns off the fan. This mode can be activated from any charge setting.
When activated the charging mode icons will flash while in this mode. For example, if the
charger is in fast AGM mode before entering Quiet Night Mode, the fast AGM mode icons will
start flashing once the charger goes into Quiet Night Mode. The original AGM fast Charging
mode will be remembered.
6.3 Recondition Mode
Recondition mode can be used on AGM batteries only to give the battery a specialised
charge if the battery has not been used in some time. We recommend you consult your
battery manual or vendor when using Recondition mode as it can shorten battery life.
Recondition mode is selected using the standard selection via the mode button as described
above. Note that in recondition mode the charge stage will stop at stage 6 as shown below.
Once the display reaches this stage the recondition mode has finished.
BATTERY
240V AC
Note: that #6 (RECON) only appears
while in AGM (RECON) mode.

14
Charging Mode
STD Slow Mode
STD Fast Mode
AGM Fast Mode
Lithium Slow Mode
Lithium Fast Mode
Lithium Activation Mode
Max Charging
Current
4A
22A
22A
7A
22A
22A
Recommended Battery Capacity
10-50AH
44-300AH
44-300AH
15-100AH (Related to battery's BMS setting)
44-300AH (Related to battery's BMS setting)
44-300AH (Related to battery's BMS setting)
7.0 Battery Type & Capacity
This charger is suitable for 12V Normal Lead Acid, Sealed, Gel and 12V LiFePO4 Batteries
between 15-300Ah.
8.0 Charging Profile
Battery Diagnostic and Precharge (Stage 1):
Check the battery voltage to make sure battery connections are good and the
battery is in a stable condition before starting charging the battery.
Desulphation (Stage2):
Detects sulfated batteries. Pulsing current and voltage (1'' charge and 0.5''
discharge), removes sulfate from the lead plates of the battery restoring the
battery capacity.
If the change of battery voltage exceeds the voltage setting during charging and
discharging, it enters the next stage 4 hours later; if the change is less than 3V, it
enters the next stage without desulphurization repair (in about 10 seconds).
Only for STD/AGM batteries.
This model is controlled by a microprocessor with 9-stage charging profiles for charging
batteries.
The microprocessor senses the condition of the battery to provide the right current and
voltage to the battery (charging profile). This will provide the best effect on charging and
protect the health of the batteries.
1
2

15
Soft Start (Stage 3):
Initial battery test to determine battery condition. If the battery is severely
discharged, the charger will begin the Soft Start stage. Charging starts with
reduced current until battery voltage reaches a normal condition for charge.
Bulk (Stage 4):
Major charging stage where the battery receives the majority of its capacity. The
charger delivers maximum current until the terminal voltage has risen to the full
charge level for normal battery.
Absorption (Stage 5):
Completes the charge up to virtually 100% at a constant voltage. The current
tapers off after the current reaches the minimum level.
Recondition (Stage 6):
Select Recondition mode, charged by higher voltage to recondition the sulfate of
the AGM battery to extend battery life. This stage is available only for AGM
batteries.
Analysis (Stage 7):
Test if the battery can hold capacity.
Float (Stage 8):
Low constant voltage with minimum charge current, after the battery is fully
charged.
In AGM mode, the charger will transfer from stage 8 to stage 1 when battery
voltage is less than 12.8V.
In Lithium mode, the charger will transfer from stage 8 to stage 1 when battery
voltage is less than 13.1V.
Pulse (Stage 9):
Maintain the battery at 95-100% capacity. The charger monitors the battery
voltage and gives a pulse when necessary to keep the battery fully charged.
Only for STD/AGM batteries.
3
4
5
6
7
8
9

15
12V
SLOW
CURRENT (A) VOLTAGE (V)
4~14V ok
≥ 15V Er2
2A until voltage
drops less than
2V
1A until
10V
Increasing
voltage until
14V 4A
Current
Reduction
14.4V
/
Check if
voltage drops
less than 2V
13.10-14.2h 13.0-14.4
12V
GEL
FAST
4~14V ok
≥ 15V Er2
2A until voltage
drops less than
2V
1A until
10V
Increasing
voltage until
14V 22A
Current
Reduction
14.4V
/
Check if
voltage drops
less than 2V
13.10-14.2h 13.0-14.4
12V
AGM
FAST
4~14V ok
≥ 15V Er2
2A until voltage
drops less than
2V
1A until
10V
Increasing
voltage until
14V 22A
Current
Reduction
14.7V
/
Check if
voltage drops
less than 2V
13.10-14.2h 13.0-14.7
12V
RECON
4~14V ok
≥ 15V Er2
2A until voltage
drops less than
2V
1A until
10V
Increasing
voltage until
14V 22A
Current
Reduction
14.7V
Max 15.7V,
2A
Check if
voltage drops
less than 2V
13.10-14.2h 13.0-14.7
Test Max 4h 5-8V 2’
8-10V 9h Max 36h Max 2h 1.5”
4h charge cycle
restarts if voltage
drops
Charge cycle
restarts if voltage
drops
12V Standard / Gel / AGM Batteries
1 2 345678 9
16

15
12V
LiFePo4
Slow
CURRENT (A) VOLTAGE (V)
4~14V ok
≥ 15V Er2 /1A until 10V
Increasing
voltage until
14.5V 7A
Current
Reduction
14.5V
/
Check if
voltage drops
less than 2V
Full charged,
recharge if
voltage under
/
12V
LiFePo4
Fast
4~14V ok
≥ 15V Er2 /1A until 10V
Increasing
voltage until
14.5V 22A
Current
Reduction
14.5V
/
Check if
voltage drops
less than 2V
/
Test Max 4h 5-8V 2’
8-10V 9h Max 36h Max 2h 1.5”
4h charge cycle
restarts if voltage
drops
Charge cycle
restarts if voltage
drops
12V LifePo4 Batteries
Full charged,
recharge if
voltage under
1 2 345678 9
17

18
9.0 Charger Error Codes
Er1 - Red LED Flash : Reverse polarity error
- During diagnostics stage 1
POWER
CHARGING/
FAULT
POWER
CHARGING/
FAULT
POWER
CHARGING/
FAULT
POWER
CHARGING/
FAULT
POWER
CHARGING/
FAULT
Er2 - Red LED Solid : Faulty battery condition
Battery voltage is ≥ 15v
- During diagnostics stage 1
Er3 - Red LED Slow Blink: Fault code during initial
charge step. Battery voltage doesn’t reach a normal
condition for charging.
- During initial soft start stage 3
Er4 - Red LED Solid : Battery voltage variance exceeds 2v
after pulse current test. Battery not holding charge / wont
charge.
- During analysis stage 7
Er5 - Red LED Solid : Pulse current voltage exceeds 2v.
Battery not holding charge / wont charge.
- During desulphation stage 2
If Red LED indicator lights up or blinks and LCD display icons illuminate, the
following occurs: