Projecta AC040 User manual

8 STAGE SWITCHMODE
CHARGE N’ MAINTAIN
BATTERY CHARGER
P/No’s. AC040, AC080

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IMPORTANT SAFETY INFORMATION
Please read this manual thoroughly before use and store in a safe place for future
reference.
WARNINGS
• Explosive gases may escape from the battery during charging. Prevent flames and sparks.
Provide adequate ventilation
• Before charging, read the instructions
• For charging 12 Volt lead acid batteries ONLY (AC040 6/12 Volt)
• Disconnect the 240V mains supply before making or breaking the connections to the battery
• The battery charger must be plugged into an earthed socket-outlet
• Connection to supply mains is to be in accordance with national wiring rules
• Do not attempt to charge non-rechargeable batteries
• Never charge a frozen battery
• If the AC cord is damaged do not attempt to use. It must be replaced or repaired by a
qualified person
• Corrosive substances may escape from the battery during charging and damage delicate
surfaces. Store and charge in a suitable area
• Ensure all vehicle accessories including lights, heaters, appliances etc are turned off prior to
charging
• This appliance is not intended for use by young children or infirm persons unless they
have been adequately supervised by a responsible person to ensure that they can use the
appliance safely
• Young children should be supervised to ensure that they do not play with the appliance

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8-STAGE AUTOMATIC CHARGING
The AC040 and AC080 are fully automatic battery chargers with 8 charge stages.
Automatic charging protects your battery from being overcharged so you can leave the
charger connected to the battery indefinitely.
8-stage charging is a sophisticated charging technique that gives your battery longer life and
better performance compared to using traditional chargers.
Projecta’s CHARGE N’ MAINTAIN chargers are suitable for most 12V automotive, marine
and deep cycle batteries. (AC040 also suits 6V batteries).
The 8 charge stages are:
Battery Rescue, Soft Pulse, Pulse Charge, Soft Start, Bulk, Absorption, Battery Test and Float.
BATTERY RESCUE
Applies a high voltage to break down the Lead Sulfate build up in heavily sulfated batteries.
SOFT PULSE
Pulses a small current as the battery is starting to take charge.
PULSE CHARGE
Increases the pulse current as the battery is starting to take charge.
SOFT START
This is a preliminary charge process that gently introduces power to the battery, protecting
the battery and increasing battery life.
BULK (CONSTANT CURRENT)
The Bulk stage reduces charging time by charging the battery at the maximum rate (constant
current) to a set voltage, at which point the battery is approximately 80% charged.
ABSORPTION (CONSTANT VOLTAGE)
The absorption stage charges the battery to 100% by adjusting the charge rate allowing the
battery to absorb more power.
BATTERY TEST
The analysis mode tests the battery to ensure that it has taken the charge; if the battery
passes the test the charger will proceed to the float stage.
FLOAT
The Float stage maintains the battery at 100% charge without overcharging or damaging
the battery. This means the charger can be left connected to the battery indefinitely.

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FEATURES
MODE BUTTON
Toggles through the different features of the charger on the LCD display
Toogles through the following:
Battery voltage: Shows the battery voltage.
12V Slow charging – AC040 chargers to 14.4V/1.0A
AC080 chargers to14.4V/2.0A
12V Fast charging – AC040 chargers to 14.4V/4.0A
AC080 chargers to14.4V/8.0A
12V Winter charging – AC040 chargers to 14.7V/4.0A
AC080 chargers to14.7V/8.0A
6V Charging (AC040 only) – Chargers 6 Volt batteries
INTERACTIVE LCD SCREEN
The screen whilst charging will show the battery voltage and battery gauge. The screen is
handy while setting up.
SWITCHMODE TECHNOLOGY
Using the latest technology in battery chargers, switchmode chargers convert 240V AC
power to 12V DC power using electronic components unlike traditional battery chargers that
rely on heavy transformers. This allows the charger to be lightweight and compact without
sacrificing on performance.
SPARK-FREE AND POLARITY PROTECTED
All Projecta Charge ‘N’ Maintain battery chargers are spark-free and are protected against
accidental reverse connection making them safer to use around batteries.
WEATHER PROOF IP65
The chargers are IP65 rated which means that can by used outside without getting
damaged. Although the charger is a 240VAC device care should be taken that the plug is
not submersed in water.

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CHARGING INSTRUCTIONS
STEP 1 – CHECK THE ELECTROLYTE LEVEL
Prior to charging the battery, remove the vent caps and check the electrolyte level (not
required on sealed & maintenance free batteries). The electrolyte should be 6mm (1/4”)
above the battery’s plates. If low, top up with distilled water to the correct level and refit
the vent caps.
STEP 2 – CONNECT TO BATTERY
There are three options for connecting to a battery.
Step 2A – Connecting to a battery that is out of the vehicle
Step 2B – Connecting to a battery fitted to a vehicle
Step 2C – Permanent hard wiring connection to a battery
STEP 2A – BATTERY OUT OF VEHICLE
Connect the RED lead (battery clip) from the charger to the Positive (+) battery post.
Connect the BLACK lead (battery clip) from the charger to the Negative (-) battery post.
STEP 2B – BATTERY IN VEHICLE
Determine if the vehicle is Positively (+) or Negatively (-) earthed. Negatively earthed
vehicles have a cable (usually black) from the Negative battery terminal to the vehicle’s
chassis.
Negatively earthed (most vehicles)
Connect the RED lead (battery clip) from the charger to the Positive (+) battery terminal.
Connect the BLACK lead (battery clip) from the charger to the vehicle’s chassis away from
the fuel line or moving parts.
Connection in vehicle
(negatively earthed)
Connection out of vehicle

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Positively earthed
Connect the BLACK lead (battery clip) from the charger to the Negative (-) battery terminal.
Connect the RED lead (battery clip) from the charger to the vehicle’s chassis away from the
fuel line or moving parts.
STEP 2C – PERMANENT HARD WIRING
It is possible to hard wire the DC charging leads to the battery for permanent installations.
Use the supplied fused wiring harness.
AC040, uses 7.5A fuse
AC080, uses 10A fuse
Connection:
1. Connect the RED lead (with inline fuse and ring terminal) to the Positive (+) battery post,
remove the supplied fuse.
2. Connect the BLACK lead (with ring terminal) to the Negative (-) battery post.
3. Fit the correctly rated fuse.
If the charger is used in a Permanent/Hard Wired application and the vehicle will not be
used for some time, it is best to leave the charger connected to mains power (turned ‘On’)
so that it can maintain the battery fully charged.
Ensure any modification to the 240V mains lead is carried out by a qualified person and that
connection to supply mains is in accordance with National wiring rules.
STEP 3 – CONNECT TO 240V MAINS POWER
Connect the battery charger to the 240V mains powered socket and turn on the mains power.
STEP 4 – SET CHARGE RATE
The charge rate should be set according to the size of the battery. To set, press the MODE
button repeatedly until desired setting is displayed. See the recommended charge rates for
various battery sizes in the table at top of page 7. (Not all outputs are available on all models)
Connection in vehicle
(positively earthed)
Inline fuse Ring terminal

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STEP 5 – SET BATTERY TYPE
The AC040 & AC080 come with winter mode so when the temperature of the battery is
close to 0°C degrees (<5°C) winter mode should be set.
Toggle through the Mode button to do this.
STEP 6 – CHARGING
Whilst Charging the LCD screen will show the battery voltage and a battery gauge at the
bottom will show the status of Charge. When fully Charged the battery gauge will be fully
highlighted and the word “FULL” will be displayed.
If the RECON symbol is shown on the display then the charger is trying to repair the battery.
Which will take longer to charge.
If there are any faults during charging refer to the “Fault & Errors” explanation at the
bottom of this page.
STEP 7 – DISCONNECTION
Ensure the 240V mains switch is turned off and the charger is disconnected from the 240V
mains power.
Battery out of vehicle
Remove the BLACK lead (battery clip) from the battery.
Remove the RED lead (battery clip) from battery.
Battery in vehicle
Remove the chassis connection.
Remove the battery terminal connection.
FAULTS & ERRORS
There are 4 possible error signals that may be displayed. These are explained in the
following table:
Amps Deep Cycle (Ah) Automotive (CCA) Marine (MCA) Time (Hrs)
1 Amp (AC040 Slow) 7–24 40–140 55–200 7–26
2 Amp (AC080 Slow) 14–50 80–300 110–400 7–26
4 Amp (AC040 Fast) 24–80 140–480 200–650 6–24
8 Amp (AC080 Fast) 50–160 300–1000 400–1300 6–24
F1 1. No clamps connected.
2. Short circuit
3. Reverse polarity connection
F2 Loose clamps during charging
F3 Battery voltage is too high
F4 Bad battery

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Part No. AC040 AC080
Input (nominal) 240VAC, 50Hz
Input Power 35.5W @ 6V, 63.5W @ 12V 128.5W
Output Voltage 6/12V 12V
Output Current 1, 4A 2, 8A
Minimum Start Voltage 2.0V
Back Drain 2mA
Charge Control
Battery Rescue Part 1 Battery voltage increases 500mA up 16.0V for 600mA up 16.0V for
>14.4V immediately 5 seconds, until voltage 5 seconds, until voltage
reduces to 13.5V reduces to 13.5V
Battery Rescue Part 2 Battery voltage increases 500mA up to 17.0V, 600mA up to 17.0V,
>14.4V after stage 1 if voltage drops to 13.5V if voltage drops to 13.5V
continue charging or continue charging or
2 hour limit then fault. 2 hour limit then fault.
Soft Pulse 2-6.0V 0.8A for 1 second then turn of for 2 seconds 2 hour limit
then fault
Pulse Charge part 2 6.0-10.5V Set current to 0.8A for 5 seconds then 2A for 5 seconds.
2 hour limit then fault.
Soft Start 10.5-12.0V 8 hour timeout then 1A 2A
transits to bulk
Bulk Set current to 13.6V (12V), Set current to 13.6V
6.8V (6V)
Absorption Constant voltage (12V) 14.4V (Normal), 14.7V (Winter),
7.2V (6V)
Absorption transits at following set points Slow(1A): <0.5A Slow(2A): <0.5A
Fast(4A): <0.6A Fast(8A): <1.2A
Winter(4A): <0.6A Winter(8A): <1.2A
6V(4A): <0.6A
Absorption timeout, transits to Analysis 6 hours
Analysis 60 second timeout, if battery drops <12.5V set F4 fault
Float (12V) 13.8V 2 min on, (12V) 13.8V 2 min on,
2 min. off (6V) Cutout 7.2V, 2 min. off
Cut in 6.5V
Battery Range
Deep Cycle 7-80Ah 14-160Ah
Automotive 40-480CCA 80-1000CCA
Marine 55-650MCA 110-1300MCA
Size (mm) 225 x 60 x 90 250 x 68 x 95
Weight 0.66kg 0.87kg
SPECIFICATIONS

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FREQUENTLY ASKED QUESTIONS
Q. How do I know if the battery is charged?
A. The charger will indicate full on the display. Alternatively use a Battery Hydrometer
(Projecta Part No. BH100). A reading of 1.250 or more in each cell indicates a fully
charged battery.
Q. I have connected the charger properly but the Charger won’t start charging?
A. In some cases batteries can be flattened to the point where they have very little or no
voltage. This can occur if a small amount of power is used for a long time, for example
a map reading light is left on for a week or more. Projecta 8 Stage chargers are
designed to charge from as little as little as 2.0 Volts.
If the voltage is lower than the voltages stated above use a pair of booster cables to
connect between two batteries to provide more than 2.0 Volts to the battery being
charged. The charger can then start to charge the battery and the booster cables can
be removed.
PRODUCT OVERVIEW
Spark free
& polarity
protected
Weatherproof IP65
P/No. AC040 P/No. AC080
Fused wiring harness
or battery clips
Interactive
LCD screen
Automatic charging
60
225
68
250

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Q. Can I use the charger as a power supply?
A. Projecta 8 Stage chargers are designed to only supply power to the battery clips when
they are connected correctly to a battery. This is to prevent sparks during connection
to the battery or if connected incorrectly by mistake. This safety feature prevents the
charger from being used as a ‘Power Supply’
Q. How can I tell what stage the battery charger is in?
A. Look at the gauge at the bottom of the display and voltage to determine at what point
the charger is at.
Q. I have connected my charger to the battery and the display shows 0.00V.
A. Check to make sure the battery charger clamps are correctly connected to the battery
posts or battery terminal.
Check to make sure the battery clamps are connected Positive (Red) clamp to the
positive post of the battery and the Negative (Black) clamp is connected to the
Negative post on the battery.

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NOTES

IS435
Issue 2 29.09.21
WARRANTY STATEMENT
APPLICABLE ONLY TO PRODUCT SOLD IN AUSTRALIA
Brown & Watson International Pty Ltd of 1500 Ferntree Gully Road, Knoxfield, Vic.,
telephone [phone], fax [phone], warrants that all products described in
its current catalogue will under normal use and service be free of failures in material and
workmanship for a period of one (1) year (unless this period has been extended as indicated
elsewhere) from the date of the original purchase by the consumer as marked on the invoice.
This warranty does not cover ordinary wear and tear, abuse, alteration of products or
damage caused by the consumer.
To make a warranty claim the consumer must deliver the product at their cost to the original
place of purchase or to any other place which may be nominated by either BWI or the retailer
from where the product was bought in order that a warranty assessment may be performed.
The consumer must also deliver the original invoice evidencing the date and place of
purchase together with an explanation in writing as to the nature of the claim.
In the event that the claim is determined to be for a minor failure of the product then
BWI reserves the right to repair or replace it at its discretion. In the event that a major
failure is determined the consumer will be entitled to a replacement or a refund as well as
compensation for any other reasonably foreseeable loss or damage.
This warranty is in addition to any other rights or remedies that the consumer may have
under State or Federal legislation.
IMPORTANT NOTE
Our goods come with guarantees that cannot be excluded under the Australian Consumer
Law. You are entitled to a replacement or refund for a major failure and compensation for
any other reasonably foreseeable loss or damage. You are also entitled to have the goods
repaired or replaced if the goods fail to be of acceptable quality and the failure does not
amount to a major failure.
Distributed by
AUSTRALIA
Brown & Watson International Pty Ltd
Knoxfield, Victoria 3180
Telephone: [phone]
Facsimile: [phone]
National Toll Free: 1800 113 443
NEW ZEALAND
Griffiths Equipment Ltd.
19 Bell Avenue,
Mount Wellington,
Auckland 1060, New Zealand
Phone: [phone]
Fax: [phone]