PowerTran GP-CZ1206 User manual

Model Number
Input Voltage
Maximum Input Current(Max.)
Voltage Charging
Selectable Charging Current
Battery Capacity & Battery Type
Over-Temperature Protection
Reverse-Polarity Protection
Short-Circuit Protection
No-Load Protection
Dimension / Weight
Operating Temp / Humidity
Storage Temp / Humidity
Safety / EMC Approvals
Wrong-Battery Protection
110 VAC / 230 VAC
GP - CZ1206
110 VAC / 2.5A, 230 VAC / 1.3A (Max.)
14.7 VDC for Snow Mode
14.4 VDC for Normal Mode
200 × 90 × 44.8 (mm) / 0.7 kg (Max)
CE / FCC / ETL / GOST / RCM
-20 ~ +50 °C / 95%
-20 ~ +85 °C / 10 ~ 95% RH
1A for Motorcycle
4A for Car / Van
6A for Truck / RV
YES
Automatic power reduction at high ambient temperature.
YES
No charging, the charge-indicating LED is off.
YES
No charging, the charge-indicating LED is off.
YES
If the battery produces an unusual voltage to the charger, then there
will be no charging and LED will not illuminate.
YES
Standby mode without any charging.
3 ~ 200 Ah, 12V
Lead-Acid
(Wet, MF,AGM, GEL)
Snow Mode
Normal Mode
Float
Desulphation Diagnosis Bulk Absorption Supervision Float
Current
Voltage
Time
Scooter Motorcycle Car / Van Truck / RV
Bicycle Scooter ATV Snowmobile
【Wide-Range Charging】
Mode Switch
(Non LED)
This switch selects operating modes among standby, scooter / ATV, motorcycle, car / van, and
truck / RV.
Snow Switch
(Green LED)
Product Features
Specifications
CHARGING CURVE
Operating Procedure
Selective Switches
a. Before charging the battery installed in a vehicle, please turn off all the electrical equipment including lights and
other accessories connected to the vehicle.
b. Please identify the polarity of the battery: the POSITIVE (POS, P, +) and NEGATIVE (NEG, N, –) pole.
c. Please inspect which battery pole is grounded (connected to the vehicle chassis). The negative pole is usually
(but not always) grounded.
d. For charging a battery installed in a vehicle, please connect the POSITIVE (RED) and NEGATIVE (BLACK) clip
of the charger to the POSITIVE (+) and NEGATIVE (-) pole (or the vehicle chassis) of the battery respectively.
Please ensure the NEGATIVE (BLACK) clip should not be located near the fuel-pipe, carburetor and fuel
tubess Sheet-metal parts should be free from any clip.
e. For charging the battery which is not installed in a vehicle, please connect the RED and BLACK clip to the
POSITIVE and NEGATIVE pole respectively.
f. After plugging the AC power cord of the charger into the AC outlet, all charge-indicating LEDs
scanned successively.
g. Press the mode button to select vehicle type. This sets the battery maximum charging current (refer to
specifications).
This switch selects operating modes among Snow mode (14.7V or 29.4V ) and normal mode
(14.4V or 28.8V ).
Snow mode is proposed for AGM batteries or low temperatures.
Please follow the charging instructions of battery manufacturers.
Charging Current Oered by GP - CZ1206
Green
Green
Green
3 ~ 20 Ah (7 Ah)
14 ~ 80 Ah (55 Ah)
20 ~ 150 Ah (95 Ah)
Max 60 Ah
Max 150 Ah
Max 200 Ah
3 ~ 20 hrs (7 hrs)
3 ~ 20 hrs (14 hrs)
3 ~ 25 hrs (16 hrs)
Charging Current LED Color Battery Capacity
(typical capacity)
Battery Capacity
(maintenance)
80% Charging Time
(typical time)
1A for Scooter / ATV
4A for Motorcycle
6A for Car / Van
Blue
Red
Charge-indicating
Signal
Fault-indicating
Signal
LED is off: Standby mode.
LED is blinking: Charging is progressing.
LED is on: Charging has been completed.
LED is off: No fault.
LED is blinking: Battery is unstable.
LED is on: Battery is malfunctioning or charger is damaged.
【CHARGING STEPS】
【EXPLANATION OF CHARGING STEPS】
1. Desulphation/Desulfurization:
Desulphation/Desulfurization revives the battery via a series of current pulses dissolving sulfur from the internal
battery poles to activate chemical reaction.
2. Diagnosis:
The charging current is set to a relatively low level while the microcontroller is diagnosing physical
conditions of the battery.
3. Bulk Charging:
This is a high current charge to minimise charge time.
4. Absorption:
In this stage, the battery voltage is returned to its normal fully charged level and the charging
current is gradually decaying to nil.
5. Supervision:
The microcontroller supervises the voltage decline of the fully charged battery from its normal level to its floating
level.
6. Float Charging:
The battery voltage is maintained at its floating level by the charger via supplying an intermittently minimal
charging current.
• Latest technology switchmode design circuitry meets safety approvals
• Spark free circuitry prevents sparks on connection and disconnection
• Low ripple current design prevents heat and gas build-up from batteries
• High efficiency (over 80%), fan-less design
• Internal temperature shielded unit keeps case cool
• Three options for charging current
• Robust design protects unit in abnormal situations.
• 6 charging steps aids and facilitates battery chemical reaction extending battery life
• Inbuilt active PFC circuitry PFC >0.95 (optional)
h. Select Snow mode for charging at 14.7 or 29.4V for AGM batteries, or where the ambient temperature is below
0º C.
i. If the charging LED continually blinks, the battery is being charged. When the charging LED is permanently on,
then the battery is fully charged.
j. If the fault indicator LED blinks, or is permanently on, then the battery will not accept a charge.

No. Problems Solutions
1
2
3
4
5
Solution 1:
CONFORMS TO
ANSI/UL STD 1236
3155878
N136
17-CZ120600AL1
TROUBLE SHOOTING
WARNING
SAFETY APPROVALS
Please check this trouble shooting guide before contacting your authorised sales or service agent.
No LEDs illuminate after
connecting the charger
to the AC outlet.
Please inspect the AC voltage connection.
The charge-indicating
LED is off but others
indicating scooter,
motorcycle, car,or
truck are on.
Solution 1: Please check the DC output is not short-circuited.
Solution 2: Please check the DC polarity is not reversed.
Solution 3: Please check the charger clips are connected to battery
poles properly.
Solution 4: Please check if the battery presents an eccentric voltage
to the charger.
Please review the battery voltage and polarity, disconnect the
charger clips, correct the mistake that has been found, and then
retry it.
After pressing and
releasing the SNOW
or MODE switch
button, the charger
remains inactive at the
standby mode.
Solution 1: Please press and hold the switch button for a minimum of 0.2
seconds and then release it to give sufficient time for the
microcontroller to receive signals.
Solution 2: Please examine whether the battery has expired or malfunctioned.
The fault-indicating
LED remains blinking.
The fault-indicating LED
remains invariably
bright.
Solution 1: Please continue to charge the extremely exhausted battery to
further evaluate whether there is any opportunity to revitalize it.
Solution 2: Please inspect whether the charging current is too large for the
battery to sustain.
Solution 1: If the fault-indicating LED remains invariably bright approximately
two hours after restarting the charger, please replace the
faulty battery with a new one.
Solution 2: If the fault-indicating LED remains invariably bright a few minutes
after restarting the charger, please consign the damaged charger
to your local distributor for RMA within the valid period of product
warranty.
To diminish the risk of electric shock, please disconnect the charger clips from the battery
poles after unplugging the AC cord from the AC outlet.
Do not attempt to charge non-rechargeable batteries.
Do not attempt to use these chargers to recharge non-12/24V lead acid batteries.
» This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction
concerning use of the appliance by a person responsible for their safety.
» Children should be supervised to ensure that they do not play with the appliance.
» The supply cord cannot be replaced. If the cord is damaged, the appliance should be scrapped.
» The battery terminal not connected to the chassis has to be connected first. The other connection is to be made
to the chassis, remote from the battery and fuel line. The battery charger is then to be connected to the supply
mains.
» After charging, disconnect the battery charger from the chassis connection and then the battery connection.
» WARNING: do not charge non-rechargeable batteries.
» During charging, the battery must be placed in a well ventilated area.
»
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS －This manual contains important safety and operating instructions
for battery charger Models CZ1206NU / CZ2404NU / CZ1204NU.
2. Do not expose the charger to rain or snow.
3. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire,
electric shock, or injury to persons.
4. To reduce risk of damage to electric plug and cord, pull by the plug rather than the power cord when
disconnecting charger.
5. An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result
in a risk of fire and electric shock. If an extension cord must be used, make sure:
a) That pins on plug of extension cord are the same number, size, and shape as those of plug on charger;
b) That extension cord is properly wired and in good electrical condition; and
c) That wire size is large enough for ac ampere rating of charger as specified 18AWG size of cord.
6. Do not operate charger with damaged cord or plug －replace the cord or plug immediately.
7. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way,
refer it to a qualified serviceman.
8. Do not disassemble charger; take it to a qualified serviceman when service or repair is required. Incorrect
reassembly may result in a risk of electric shock or fire.
9. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning.
Turning off controls will not reduce this risk.
10. WARNING －RISK OF EXPLOSIVE GASES.
a) WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATERY OPERATION. FOR THIS
REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU
USE THE CHARGER.
b) To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer
and manufacturer of any equipment you intend to use in vicinity of battery. Review cautionary marking on
these products and on engine.
11. PERSONAL PRECAUTIONS
a) Consider having someone close enough by to come to your aid when you work near a lead-acid battery.
b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
c) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
d) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye,
immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately.
e) NEVER smoke or allow a spark or flame in vicinity of battery or engine.
f ) Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery
or other electrical part that may cause explosion.
g) Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
lead-acid battery. A lead-acid battery can produce a short-circuited current high enough to weld a ring or the
like to metal, causing a severe burn.
h) Use charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low voltage
electrical system other than in a starter-motor application. Do not use battery charger for charging dry-cell
batteries that are commonly used with home appliances. These batteries may burst and cause injury to
persons and damage to property.
i) NEVER charge a frozen battery.
12. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge, always remove grounded terminal from battery first.
Make sure all accessories in the vehicle are off, so as not to cause an arc.
b) Be sure area around battery is well ventilated while battery is being charged.
c) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
d) Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. Do not
overfill. For a battery without removable cell caps, such as valve regulated lead acid batteries, carefully
follow manufacturer’s recharging instructions.
e) Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.
f ) Determine voltage of battery by referring to car owner’s manual and make sure it matches output rating of
battery charger.
13. CHARGER LOCATION
a) Locate charger as far away from battery as dc cables permit.
b) Never place charger directly above battery being charger; gases from the battery will corrode and damage
charger.
c) Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling battery.
d) Do not operate charger in a closed-in area or restrict ventilation in any way.
e) Do not set a battery on top of charger.
14. DC CONNECTION PRECAUTIONS
a) Connect and disconnect dc output clips only after setting any charger switches to “off” position and
removing ac cord from electric outlet. Never allow clips to touch each other.
b) Attach clips to battery and chassis as indicated in 15(e), 15(f), and 16(b) through 16(d).
15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE. A SPARK NEAR BATTERY MAY
CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:
a) Position ac and dc cords to reduce risk of damage by hood, door, or moving engine part.
b) Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
c) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger diameter than
NEGATIVE (NEG, N, -) post.
d) Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to
chassis (as in most vehicles), see (e). If positive post is grounded to the chassis, see (f).
e) For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS,
P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away
from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy
guage metal part of the frame or engine block.
f ) For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to NEGATIVE (NEG,
N, -) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away
from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy
gauge metal part of the frame or engine block.
g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle chassis, and
then remove clip from battery terminal.
16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. A SPARK NEAR THE BATTERY MAY
CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:
a) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than
NEGATIVE (NEG, N, -) post.
b) Attach at least a 24-inch-long 6gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, -) battery
post.]
c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.
d) Position yourself and free end of cable as far away from battery as possible －then connect NEGATIVE
(BLACK) charger clip to free end of cable.
e) Do not face battery when making final connection.
f ) When disconnecting charger, always do so in reverse sequence of connecting procedure and break first
connection while as far away from battery as practical.
g) A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment
specially designed for marine use.
The battery charger is fitted with over-temperature protection. During normal charging conditions it is possible
that the output current may reduce to ensure safe and reliable battery charging.