Pro-tec ProCharge User manual

Charge
®
Pro
Professional
ProCharge
Instruction Manual
ProCharge is an automated 12-Volt Battery Charging System that will
charge and maintain up to six batteries at a time @ 5 Amps and with
extensions 12 batteries @ 2.5 Amps. ProCharge delivers a voltage more
appropriate for smaller batteries.
2650-1122-00
Rev. B
12
ProTec International LLC
1832 Cedar Oak Road
Placerville, CA 95667
Phone [phone]

CONGRATULATIONS!
You have made a purchase of ProTec International ProCharge designed
to charge 12 Volt batteries. The system is fully automated with LED’s
indicating unattended viewing status.
ProCharge
Charges ------------------------------------------------------12 Volt Batteries
Input (110 Volt Version)------------------------------- 115 VAC @ 5 Amps
Input (220 Volt Version) ----------------------------220 VAC @ 2.5 Amps
Charging output mode----------------------------------------- 5 Amps Max.
Maintenance output mode----------0 to 2.5 Amp variation as needed
Leads ---------------------------------------------------------------- 6 ft. 18 GA.
Size ---------------------------------------------------------26” W 8” H 3.25” D
Weight ----------------------------------------------------------------------31 lbs.
Optional AC-8 Jumper Leads ------------------------------------- Set of six
WARRANTY AND SERVICE INFORMATION
Warranty and service claims sent to the ProCharge
service department must be transportation prepaid and
accompanied with dated proof of purchase. This warranty
applies only to the original retail purchaser and is non-
transferable. Damage incurred during return shipments
is not covered under this warranty. It is the responsibility
of the shipper (the original retail purchaser returning
the ProCharge Charger) to package the charger/tester
properly to prevent any damage during return shipment.
Repair costs for such damages will be charged back to
the shipper (original retail purchaser returning ProCharge
Charger). Protect the product with plenty of packing/
cushioning such as crumpled up newspaper.
LIMITED WARRANTY (12 MONTHS FROM DATE OF
PURCHASE)
ProTec International warrants to the original retail
purchaser that this product will be free from defects in
material or workmanship for a period of twelve (12) months
from the date of original retail purchase. When ProTec
International determines a product failed due to defects
in material or workmanship within this 12-month warranty
period, the product will be repaired or replaced for the
original retail purchaser only. This warranty is limited to the
repair or replacement of parts in the ProCharge Charger
and the necessary labor by ProTec International to effect
the repair or replacement of the ProCharge Charger. In no
event shall ProTec International be responsible for special,
incidental or consequential damages or costs incurred
due to the failure of the product such as: improper use,
accident, water damage, abuse, unauthorized repairs
or alterations, but not limited to these acts, voids this
warranty. ProTec International disclaims any liability or
consequential damages due to breach of any written
or implied warranty of the ProCharge Charger, or any
attempted service done by anyone other than ProTec
International
FOR SERVICE CONTACT: ProTec International LLC
1832 Cedar Oak Road, Placerville, CA 95667
Phone [phone]
CONTENTS
Safety Instructions----------------------------------------------------------- 3
Personal Safety -------------------------------------------------------------- 4
Setting Up the ProCharge ------------------------------------------------- 5
Inspecting The Battery------------------------------------------------------ 6
Hooking up the Clamps ---------------------------------------------------- 7
Reading the Indicator Lights --------------------------------------------6-7
Disconnecting the ProCharge -------------------------------------------- 8
Hookup Potential (3 units together and optional leads) ------------ 9
What to Expect from your ProCharge ---------------------------------10
Warranty and Service Information -------------------------------------- 11
Contact Information --------------------------------------------------------12
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SAFETY INSTRUCTIONS
WARNING:
Lead Acid Batteries are Dangerous! During use and charging they
may generate EXPLOSIVE Hydrogen Gas. This means YOU MUST
carefully read all of the safety and operating instructions before using the
ProCharge. Be sure you understand all of the safety instructions in this
manual and on the ProCharge before attempting to connect, charge, or
work with a lead acid battery.
What To Expect From The ProCharge
The Professional ProCharge Charger is equipped with sophisticated
circuitry that will:
• Check Each Battery’s Condition The ProCharge will indicate bad batteries
that are sulfated or have bad cells. This allows the battery to be replaced
without unnecessary charging.
• Fully Charge Six 12 volt Batteries (5 Amps. each). With the optional Jumper
Lead Kit the ProCharge can charge up to twelve batteries at 2.5 Amps each.
• Maintain Each Battery The ProCharge provides a separate charging station
for each battery. With the optional kit, each station can maintain two batteries.
• Provide Worry Free Attention The ProCharge has safe circuitry that
automatically adjusts the volt/current relationship in order to maintain the
battery at full charge. If the voltage drops below 12.5 volts, the ProCharge will
automatically charge the battery with up to 5 Amps. When the battery reaches
the threshold again the unit goes into maintenance mode.
• Maximize Battery Life The ProCharge Charger is designed to maximize the
life of a serviceable lead acid battery. A serviceable battery is a battery that
is not defective or damaged. The ProCharge is fully compatible with gelled
electrolyte (gel-cell) batteries (sometimes used in place of liquid electrolyte
batteries in many heavy duty applications). DO NOT USE WITH DRY
CELL, NICKEL CADMIUM, and NICKEL METAL HYDRIDE OR SIMILAR
BATTERIES.
• Increase Multiple Battery Charging Capability The ProCharge provides the
opportunity to charge more batteries with less time spent charging defective
batteries that need to be replaced.
• Provide Valuable Protection The ProCharge maintains batteries while they
are uninstalled. Maintaining a battery increases its life and protects its capacity.
• Maintain Batteries Not In Use. Some examples are automobiles under
long term repair, farm machinery and eet vehicles in repair or storage.
The ProCharge is ideal for rental equipment not in use or for charging and
maintaining batteries for replacement. The ProCharge can be used to re-
charge, check and maintain all starting and deep cycle batteries. Each Bus
ProCharge can charge, check and maintain up to six batteries. With the
optional Jumper Lead Kit twelve batteries can be charged or maintained.
• Provide Easy Care The ProCharge is designed for easy care and
maintenance. Occasional cleaning of the leads and housing will help keep
the unit looking new, and give you many years of satisfaction. CLEANING
PROCEDURE: Unplug the ProCharge and use a slightly dampened cloth to
clean the housing and lead sets. DO NOT use solvents or soaps.
• Provide Long Lasting Performance The ProCharge Charger Tester has
been designed and manufactured in the USA to provide superior performance.
Quality is built in and assured with circuit burn-in, computerized testing and
inspection.
• Fuse Protected Each charging station is protected by a replaceable AC fuse.
GENERAL SAFETY RULES FOR SAFE OPERATION
Batteries are dangerous. ProTec Internationsal provides the following
Warnings for your safety:
1. Use the ProCharge only on 12 Volt LEAD ACID AND GELLED
ELECTROLYTE (GEL-CELL) Batteries. DO NOT attempt to use on other
types of batteries (Dry Cell, Nickel Cadmium, Nickel Metal Hydride, etc.)
commonly found in small home appliances. This may cause the batteries to
burst, resulting in damage or injury to person and/or property.
2. DO NOT use the ProCharge on batteries that are in use or that are
installed. Remove batteries from the vehicle and take to a properly installed
ProCharge location.
3. DO NOT use attachments with the ProCharge that are not approved or sold
by ProTec International. Non-approved attachments may result in injury,
electric shock, or re and voids the warranty.
4. When disconnecting the power cord from the wall, grasp the plug and pull.
Never pull the cord, it may damage the plug and/or the cord.
5. Place the power cords in a location where they will not be stepped on,
tripped over, or subjected to stress or abuse of any kind.
6. Never operate the ProCharge if any portion of its housing, cords or
attachments appear to be damaged in any way. If damage has occurred,
have it inspected and serviced by ProTec International.
7. If the ProCharge has been dropped, received a sharp blow, or abused in any
way, have it inspected and repaired by ProTec International if necessary.
8. Do not use an extension cord to operate the ProCharge. An inadequate
extension cord could result in re or explosion due to a large number of
batteries being charged and will not provide the AC amperage rating needed
by the ProCharge.
9. Each ProCharge Station has its own AC fuse. Other than this fuse
replacement, ProTec International should be contacted for trouble shooting
and instructions on how to repair or replace parts and charging stations. Any
unauthorized repair, tampering or incorrect assembly may result in re or
electric shock and voids the warranty. Check with ProTec International for
instructions.
10. To prevent injury during cleaning or maintenance, disconnect all batteries
and move them away from the unit. Unplug the ProCharge from the wall
outlet (grasping the plug). Use a slightly dampened cloth to clean the
housing and lead sets. Do not use solvents or soaps.
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2511-2433
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ProTec International
©ProTec International
ProCharge Series
1
®
Charge
Pro
ProCharge
ProTech International LLC
1832 Cedar Oak Road
Placerville, CA 95667
Phone [phone]
rge Series
11. NEVER attempt to charge a frozen battery. Allow the battery to return to room
temperature before connection.
12. ALWAYS use the ProCharge in an open and well-ventilated area. The area
should be dry and free of trash, debris and combustibles.
13. WARNING! Explosive Hydrogen gas may be present around batteries.
14. Do not use the ProCharge in direct sunlight or adverse weather conditions
such as rain or snow.
15. Mount the ProCharge on a secure wall location at least two feet above the
batteries being charged. This prevents acid drips and spills from landing on the
ProCharge during battery lling or specic gravity testing. This also prevents
battery fumes from reaching the ProCharge.
16. Do not place small objects or tools on the top edge of the mounted ProCharge
unit.
17. NEVER use the ProCharge in or on any boat or watercraft. You must remove
the battery from the boat or watercraft and charge the battery at the properly
installed location of the ProCharge unit.
18. DO NOT install the ProCharge where it will be exposed to moisture, inclement
weather nor around combustibles, ammable liquids or vapors and
trash.
SAFETY INSTRUCTIONS Cont.
PERSONAL SAFETY PRECAUTIONS
ProCharge HOOKUP POTENTIAL
Charge up to 36 12-Volt batteries
1. Wear protective goggles or a full-face shield.
2. Wear protective clothing. Leave no exposed skin.
3. Have plenty of fresh water and hand soap available for use if acid
should contact your eyes, skin or clothing.
4. Have someone close by in the event you need emergency assistance
when working with a battery.
5. Remove all metal objects (pens, tools, jewelry, etc.) from your body.
These items can create a direct short between the battery terminals
and can cause serious burns.
6. DO NOT carry tools or metal objects within the vicinity of a battery.
These items can fall on the battery terminals creating a high current
short. This could result in a re, burns, explosion, etc.
7. DO NOT touch your face, eyes or other body parts with out rst
washing your hands. Battery acid can burn and irritate eye and skin
tissue.
8. DO NOT allow any source of ignition in the area of a battery. Keep
all ame and spark producing devices out of the area and NEVER
SMOKE near a battery.
9. Use the one hand rule! Keep one hand in your pocket whenever you
make an electrical connection. This reduces the risk of electrical shock
to the user.
• Each station delivers 5 Amps to one battery
• With optional AC-8 lead sets each station
delivers 2.5 Amps to each battery
• In order to charge 36 batteries follow the steps
below:
Hook 3 units together by
plugging the next unit into the
AC plug provided on the left end
of the ProCharge. Make sure
the power source supplied to
the rst ProCharge is adequate.
A typical 120 Volt outlet will only
supply 3 ProCharge units.
Using optional AC-8
lead sets hookup two 12
Volt batteries in parallel
to each station of
the ProCharge as
shown.
Note: If red light
ashes detach
one battery
to determine
which battery
is defective.
Recommended
for maintenance only or comparable
batteries in size and state of charge.
Step 2 Using the
Optional Lead Sets
Step 1 Hooking Up 3 ProCharge Chargers
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1SETTING UP THE ProCharge
The ProCharge Charger has two mounting keyholes. YOU MUST mount
the ProCharge to a wall that provides a secure surface. This will keep
it out of the way and prevent damage due to accidents. If needed, you
may leave the two screws slightly extended from the wall to allow easy
removal through the keyhole slots.
5DISCONNECTING THE ProCharge
The ProCharge charger is safely maintaining the battery at a full charge
when the green light is on. Simply remove the clamps and set them on
the working surface clear from the other batteries and clamps. You can
now load-test the battery.
Note: When the clamps are accidentally disconnected while charging is
in effect the ProCharge will shut the individual station off. Both indicator
lights will go out. Simply reconnect the battery.
Note:The ProCharge is designed to send a 5 amp charge only when the
circuitry determines the clamps have been attached correctly and the
battery is in need of charging. Under normal operation the clamps will not
cause any sparks if the black (-) and red (+) come in contact or if any clip
comes in contact with another.
Caution: BATTERIES ARE DANGEROUS! Be sure to practice these
proper safety rules when connecting and disconnecting batteries from
the ProCharge:
•Wear safety Glasses.
Make sure no sparks occur such as an engine starting etc.
•Make sure no tools or metal objects are in the vicinity of the
batteries
•Connect clips to a clean, properly inspected battery
•Do not disconnect a battery while charging. Wait for the green
light (OK) or ashing red (Defective).
•Handle clips carefully and set them from safely aside other
batteries and clamps.
Caution: In determining placement of the ProCharge Charger check the
following:
• Make sure the batteries can be placed at least two feet away. For
example, If the batteries are placed on the oor make sure the
ProCharge Charger is mounted securely at least two feet above, but
no more than the working length of the leads.
• Make sure the room has plenty of ventilation.
• Make sure no sparks or ames can occur near the charging area.
• Mount the ProCharge Charger away from vehicle repair or service
area.
• Never start or run an engine near the batteries being charged. It
takes very little to ignite explosive gases given off by a lead-acid
battery. Remember: You may be charging several batteries at a
time. This compounds the need for a strict safety program.
Connect the 115 Volt
ProCharge charger
to a grounded 120-Volt
AC power receptacle (115 Volt
Version) that is wired in compliance with local electrical
codes. If you do not know how to test a receptacle for proper ground,
have a qualied electrician test it for you. A grounded receptacle will
receive a plug with a round ground pin and two blade terminals. If the
outlet will not receive a plug with a ground pin, you will need a temporary
ground adapter with a metal grounding tab shown to the right. Be sure
the metal ground tab is securely screwed into the faceplate as shown.
Use this adapter only as a temporary means of connection. WARNING!
Do not alter the plug or cord on the ProCharge Charger. Any alterations
will void the warranty.
The 220 Volt ProCharge comes with all the appropriate internal
components, but the plug is removed in order for the user to attach a
plug suited to local conditions. Make sure that the green wire is wired
to the neutral and the white and black wires are wired to the two 115
prongs.
8
5
PROPER AC POWER
CONNECTIONS Metal
Grounding
Tab

2INSPECTING THE BATTERY
Remove and Inspect the battery before connecting it to a ProCharge
Charger. A clean battery and battery terminals insure proper operation of
the ProCharge Charger and the vehicle charging system.
3HOOKING UP THE CLAMPS
Each charging station has a lead set with a red positive (+) and a black
negative (-) clamp. If the ProCharge has been installed correctly, at least
two feet above the work station, the clamps should lie on a clean dry
surface.
• Check for dirty or loose terminals.
• Check for any cracks or distortion in the battery case.
• Make sure the battery is the correct group size and capacity for the
vehicle.
• Make sure the battery is clean between battery posts to avoid self
discharge.
• Check the electrolyte level.
Inspecting the electrical system If the battery and terminals have a white
or bluish crust on them, the charging system may be having problems.
Use a Charging System Analyzer to test the charging and starting system.
These problems should be corrected before the battery is installed.
4
Red & Green light = Finishing Full Charge. “Ready for Load Test”:
The battery is a least 70% charged and ready to load test and return to
service. Continued charging will take the battery to full charge.
Note:
Some batteries will pass and accept a charge, but will not be
able to pass a load test. All batteries should be load-tested after
charging.
Green light = Charged and Maintaining: The ProCharge is safely
adjusting the voltage/current relationship to maintain the battery at a
full charge. The battery can be load tested. If the battery voltage drops
below 12.5 volts, the ProCharge shifts automatically into (Red Light)
Charging Mode.
READING THE INDICATOR LIGHTS
The Professional ProCharge has two lights for each charging
station.
No Light = Check the following:
• Connections reversed. Make sure
the red spring clip is connected to the positive (+) battery post and the
black spring clip is connected to the negative (-) battery post.
• Bad connection at one or both battery posts.
• No AC power.
• The battery voltage is below 1 volt.
Red light = Charging -The Professional ProCharge is delivering up to a 5
Amp charge.
Red Light Flashing = Defective Battery: The ProCharge is designed to
detect either a sulfated battery or a bad cell. Make sure the battery posts
and clamps are clean. If the red light continues to ash the battery should
be replaced.
NOTE: Side mounted and threaded steel post batteries will require Lead
Post Adapters. Using steel bolts and connecting clamps to threaded steel
posts is not safe, and will inhibit accurate results.
• Connect the RED clamp
to the positive (+) terminal
post. Turn or wiggle the
clip on the battery post to
insure a good connection.
• Connect the BLACK
clamp to the negative (-)
battery post.
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