Projecta HDBC90 User manual

12/24V 70A MANUAL
P/No. HDBC90
WORKSHOP
BATTERY CHARGER
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IMPORTANT SAFETY INFORMATION
Please read this manual thoroughly before use and store in a safe place for future reference.
WARNING
• Explosivegases.Preventflamesandsparks.Provideadequateventilationduringcharging.
•Beforecharging,readtheinstructions.
•Forindooruse.Donotexposetorain.
•ForchargingleadacidbatteriesONLY(ofthesize&voltagespecifiedinthe
specifications table).
•Alwayschargethebatteryonthecorrectvoltagesetting.Neversetthecharger
toahighervoltagethanthebattery.
•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charger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.
•Youngchildrenshouldbesupervisedtoensurethattheydonotplaywiththeappliance.
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FEATURES
ENGINE START FUNCTION
 Startsvehicle’swithaflatbatteryafteracontrolled5minutecharge.
CHARGE METER
 ClearlydisplaystherateofchargeinAmpstoensureanaccurateandthoroughcharge.
ADJUSTABLE OUTPUT
 Adjusttherateofchargetobestsuitdifferentbatterysizes.
RAPID CHARGE
 Increaseschargerateforashortpowerfulcharge.
MULTI VOLTAGE OPERATION
 Suitableforcharging12V&24Vbatteries.
0–60MIN TIMER
 Automaticallyturnsthebatterychargeroffafterasettimewhenchargingyourbattery
inRapidChargemode.
POLARITY PROTECTION
 Fuseprotectionpreventsdamagetothechargerintheeventofreversepolarityand
short circuit.
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SPECIFICATIONS
P/No. HDBC90
 TYPE Manual
 INPUT 240V,50Hz,2000W
 OUTPUT 9.0Aat12V(setting1) 11.0Aat24V(setting1)
 23.0Aat12V(setting2) 27.0Aat24V(setting2)
  60.0Aat12V(setting3) 60.0Aat24V(setting3)
 70.0Aat12V(rapidcharge) 70.0Aat24V(rapidcharge)
 ENGINESTART 3secon,2minoff
12V 24V
 360Aat6V 360Aat12V
 MINIMUMSTART 0.0V
VOLTAGE
 BACKDRAIN 12V 24V
 5.5mA 11.6mA
 APPROVALS ElectricalSafety,EMC
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BATTERY CHARGER ASSEMBLY
 YourHDBC90isshippedwiththefollowingpartswhichrequireassemblytothemain
body of the battery charger unit:
•1xBatteryChargerHandle
•4x50mmScrews
•1xBottomStabiliserStop
•2x50mmSelfTappingScrews
•2xTrolleyWheels
•WheelAxle
•2xBlackVoltageTerminalCaps
•2x35mmWashers
•2xWheelLockingRings.
1.Placethemainbodyofthebatterychargerinanuprightposition,installthetophandle
ofthebatterychargerusingthe4x50mmscrewsasperthebelowillustration.Usea
Phillipsheadscrewdrivertotightenall4screws.
2.Laythemainbodyofthebatterychargerdownflatandfitthestabiliserstoptothe
bottomofthebatterychargerusingthe2x50mmselftappingscrewsprovided.Use
aPhillipsheadscrewdrivertotightenscrews.
3.Placethewheelaxleprovidedthroughthebottomofthebatterychargerasperthe
belowillustration.
4.Placethe2x35mmwashersoneither
endoftheaxle.
5.Fitthe2trolleywheelstoeitherendof
theaxleandsecurewiththe2xwheel
lockingring’sprovided.
6.Screwthe2xblackvoltageterminal
capsprovidedtoboththe12V&
24Voutletsonthetoppanelofthe
battery charger.
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ASSEMBLING CHARGING LEADS TO BATTERY CLAMPS
 TheHDBC90batterychargerisshippedwiththebatteryclampsdisconnectedfromthe
positive&negativechargingleads.
IMPORTANT:
•Thenegative(Black)batteryclampmustbeconnectedtothecharginglead
connectedtotheunit.
•Thepositive(Red)batteryclampmustbeconnectedtothebarecopperend
ofthesecondchargingleadsupplied.Connecttheoppositeendofthecharging
leadtoeitherthe12Vor24Voutletonthetoppanelofthebatterycharger
viathecablelugontheendofthecharginglead.
 Toconnectboththepositiveandnegativeleadstothebatteryclampsreferto
instructionsbelow:
1.Slidetherubbercoveroffthebatteryclamphandle.
2.Loosentheboltlocatedontheoutsideofthebatteryclamphandleusinga10mmsocket.
3.Feedthebearcopperendofthebatteryclampleadthroughthebatteryclamphandle
andpositionunderneaththerectangularnutaspertheillustrationbelow.
4.Refit&tightenbolttocreatefirmconnection.
5.Slidetheplasticcoverbackoverthebatteryclamphandle.
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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theelectrolytewithdistilledwatertothecorrectlevelandrefitthevent
caps.
STEP 2A – CONNECTION 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.
 CONNECTIONOUTOFVEHICLE
STEP 2B – CONNECTION 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)
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
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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.
 CONNECTIONINVEHICLE(POSITIVELYEARTHED)
STEP 3 – CONNECT TO 240V MAINS POWER
 Ensure‘CHARGERATE’dialisturnedtoOFF&connectthebatterychargerto240V
mainspower.
STEP 4 – SET BATTERY VOLTAGE
 Setthevoltageofthebatterychargerbyremovingtheblackterminalcapfromeitherthe
12Vor24Vterminalonthetoppanelofthejumpstarter.Connectthepositivebattery
cableviatheringterminaltotheappropriate12Vor24Voutlet.Ensurethebatterycharger
voltageissettothesamevoltageasthebatterybeingcharged.
STEP 5 – SET THE CHARGE MODE
NORMAL CHARGE RATE ADJUSTMENT
 Thenormalchargeratecanbeadjustedbyturningthe‘CHARGERATE’dialonthetop
paneloftheunittosetting1,2or3.Thechargerateshouldbesetaccordingtothesize
of the battery.
 Seetherecommendedchargeratesforvariousbatterysizesinthetablebelow:
 CHARGERATE  BATTERYSIZE
  DeepCycle(Ah) Automotive(CCA) Marine(MCA) Time(Hours)
 Setting1(12V) 60–180 380–1080 520–1500 7–24
 Setting1(24V) 75–220 460–1300 640–1830 7–24
 Setting2(12V) 160–460 670–2800 1340–3800 7–24
 Setting2(24V) 190–540 1130–3240 1600–4500 7–24
 Setting3(12/24V) 420–1200 2500–7200 3500–1000 7–24
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
12/24 VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
12/24VOLT 70 AMP BATTERY CHARGER WITH ENGINE START
WORKSHOP 7000
A
FUSE2x 100A
POWERON
3
10
20
30
40
50
60
12V
24V
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RAPID CHARGE
 Turnthe‘CHARGERATE’dialonthetoppaneloftheunitto‘RAPIDCHARGE’&setthe
timerbetween0-60min.TheRapidChargefunctionwillprovidea70Achargetoyour
batteryidealforwhenashortpowerfulchargeisrequired.
STEP 6 – CHARGING
 Duringcharging,theChargeMeter’sneedlewilldecrease
towardstheleft.Afullychargedbatteryisindicatedbyavery
lowreadingaccordingtothebattery’scapacityandcondition.
 Oncethispointhasbeenreached,proceedtodisconnectthe
battery(ReferSTEP7“DISCONNECTION”).
 Important:
 ChargingwillcontinueuntiltheOn/OffswitchisturnedtoOFF.
 Thebatteryandchargermustbemonitoredtoensurethebatteryisnotovercharged.
 Oncecharged,theliquidinsidethebatterymaystarttoboil.Itisrecommendedtostop
chargingwhenthisoccurstopreventdamagetothebattery.
STEP 7 – DISCONNECTION
 Turnthe‘CHARGERATE’dialtothe‘OFF’positionanddisconnectchargerfrom
the240Vsupply.
 Batteryoutofvehicle
 RemovetheBLACKlead(batteryclip)fromthebattery.RemovetheREDlead(battery
clip) from the battery.
 Batteryinvehicle
 Removethechassisconnection.Removethebatteryterminalconnection.
ChargeMeter
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ENGINE START FUNCTION
STEP 1 TO 4 – FollowSTEPS1to4ofthecharginginstructionsofthisbooklet.
STEP 5 – Turnthe‘CHARGERATE’dialtothe‘RAPIDCHARGE’function,andsetthe
‘TIMER’dialto5minutesandallowchargertochargethevehiclesbattery.
STEP 6 – Oncethe5minuteRapidChargeiscomplete,turnthe‘CHARGERATE’
dialto‘ENGINESTART’.
STEP 7 – Turnthevehicle’signitionkeytostarttheengine.
STEP 8 – Ifenginefailstostartafter3secondsrepeatinstructionSTEP5&6before
attempting to start the engine again.
NOTE:Donotrepeatthisoperationmorethan5times.
NOTE:WheninenginestartmodetheHDBC90usesincreasedpowerforashortperiod
oftime.Ensureotherappliancesconnectedtothatpowercircuitareturnedofftoavoid
fuseorcircuitbreakeroverloadinthebuildingsswitchboard.
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11
PRODUCT OVERVIEW
PositiveBattery
Clamp
NegativeBattery
Clamp
TrolleyWheels
BottomStabiliserStop
ChargeMeter
Charge/Engine
Start/OffSwitch
ChargeTimer
PowerOn
Indicator
240VMainsPowerCord
12V/24VTerminals
OutputFuse
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12
HOW TO CHANGE OUTPUT FUSE
 Thebatterychargerisfittedwith2x100Afusesdesignedtoprotectthebattery
chargeragainstreverseconnection&shortcircuit,thefuseislocatedonthetoppanel
of the battery charger.
 Toreplaceblownfuses:
1.Disconnectbatterychargerfrom240Vmainspower.
2.Disconnectbatterychargerleadsfromthevehiclesbattery.
3.Removefusecoveronthetoppaneloftheunit.
4.Removeandrefitfuses(ProjectaP/No.HDBCF100A)usinga10mmsocket.
5.Refitfusecover.
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13
FREQUENTLY ASKED QUESTIONS
Q.HowdoIknowifthebatteryisfullycharged?
A.TheChargeMeter’sneedlewilldecreasetowardstheleft.Afullychargedbatteryis
indicatedbyaverylowreading.RefertoSTEP6ofthecharginginstructionsforan
illustrationoftheChargeMeter.
 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.WhydoestheChargeMeterindicateafullychargedbatterystraightaway?
A.TherearefourpossiblereasonswhytheChargeMetermayindicateafullycharged
batterystraightaway.
1. Thebatteryisfullycharged.
2. Thebatteryhastakenasurfacecharge.
3. Thebatteryhasafaultycell.
4. TheBATTERYVOLTAGEsettingonthechargerissetlowerthanthebatteryvoltage.
Q.WhatisSurfaceCharge?
A.Batteriesunusedorleftflatforsometimebuilduparesistancetobeingrecharged.
Whenthechargerisfirstconnected,thesebatterieswilltakeasurfacecharge,andthe
ChargeMeterwillindicateafullychargedbatterywithinashortwhile.Thebattery
howeverisnotfullycharged,thechargerisvoltagesensitiveandcannotdifferentiate
betweenasurfacechargeandafullychargedbattery.Afterafewhoursthebattery
maystarttoacceptsomechargebutmostbatterieswiththisconditionwillnotrecover.
Q.WhatisaFaultyCell?
A.12Voltbatteriescontain6cellsandonefaultycellisenoughtoruinyourbattery.
Ifaftereighthoursofchargingyourbatteryisstillflat,youshouldtestthecellsusing
ahydrometer.Ifonereadingislowerthantherestitindicatesafaultycell.Itis
pointlesstocontinuecharging,asthebatteryneedsreplacing.
Q.CanIusethechargerasapowersupply?
A.No.TheHDBC90cannotbeusedasapowersupply.Donotattempttoconnectthe
clamps to anything other than a suitable battery.
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14
Q.WhatareVoltsandAmps?
 VOLTS
 Thetermvoltagereferstotheelectricalforceorelectricpotentialtodoworkbetween
twoterminalsoragoodanalogyiswaterpressureinapipe.Forexampleabatteryhas
12Voltsbetweenthepositiveandnegativeterminals,ora6Voltbatteryhas6Volts
betweenthepositiveandnegativeterminals.
 AMPS
 ThetermAMPSistheunitofmeasureusedforcurrent.Thiscanbedescribedasthe
flowofelectricchargeinacircuit.Againifyouusethewateranalogythiswouldrefer
tohowmuchwaterisflowingthroughthepipe.Forexampleifthecurrentisreading
12Ampsthenthisistheamountofenergygoingintothebattery.
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15
NOTES:
HDBC90 Instruction Manual.indd 15 4/06/12 3:02 PM

Distributedby
AUSTRALIA
Brown&WatsonInternationalPtyLtd
Knoxfield,Victoria3180
Telephone (03)97306000
Facsimile (03)97306050
NationalTollFree 1800113443
NEWZEALAND
NarvaNewZealandLtd
22–24OliveRoad
POBox12556Penrose
Auckland,NewZealand
Telephone (09)5254575
Facsimile (09)5791192 IS166 Issue21.6.12
WARRANTY STATEMENT
 Brown&WatsonInternationalPtyLtd(“BWI”)of1500FerntreeGullyRoad,Knoxfield,
Vic.,telephone(03)97306000,fax(03)97306050,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fromthedateoftheoriginalpurchasebythe
customerasmarkedontheinvoice.Thiswarrantydoesnotcoverordinarywearandtear,
abuse,alterationofproductsordamagecausedbythepurchaser.
 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the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.
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