Rossi Bt-280 User manual

12V/24V Heavy-Duty Battery

Charger

User Manual

[Revision 2.0 November 2017]

READ THIS MANUAL CAREFULLY BEFORE USE –FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY

DAMAGE AND MAY VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by

this manualmayvary in appearance,assembly,inclusions,specifications,description and packaging.

12V/24VHeavy-DutyBattery Charger

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

YouWILL be KILLED or

SERIOUSLY INJURED if you

do not follow instructions.

YouCAN be KILLED or

SERIOUSLY INJURED if you

do not follow instructions.

YouCAN be INJURED if you

do not follow instructions or

equipment damage may occur.

It is vital thatyouread and understand

this user manual before usingthe product,

including safety warnings, andany

assembly and operatinginstructions.

Keep the manual forfuturereference.

Safety precautions andrecommendations

detailed here must be fully understood

and followedtoreducetheriskof injury,

fire,explosion,electricalhazard,and/or

property damage.

Safety informationpresentedhereis

generic in nature –some advicemay not

be applicable to every product.Theterm

"equipment" refers totheproduct, be it

electricalmains powered,battery powered

orcombustion engine powered.

•Before Use-If youarenot familiar w ith

the safeoperation/handlingof the

equipment, or are in any way unsureof

any aspectof suitability or correctuse

for your application,youshould

complete training conductedby a

personor organizationqualified in safe

useand operationof this equipment,

including fuel/electricalhandling and

safety.

•Do NOT operatethe equipment in

flammable or explosiveenvironments,

suchas in the presenceof flammable

liquids, gases or dust. The equipment

may createsparks or heatthat may

ignite flammable substances.

•Keep clearof moving parts.

•Equipment may be a potential sourceof

electric shockor injury if misused.

•Do NOT operatethe equipment if it is

damaged, malfunctioning or is in an

excessively wornstate.

•Do NOT allow others tousethe

equipment unless they havereadthis

manual and areadequately trained.

•Keep packaging awayfromchildren-

risk of suffocation!Operators mustuse

the equipment correctly.Whenusing

the equipment, consider conditions and

pay due careto persons andproperty.

GeneralWorkAreaSafety

•Work areasshouldbe cleanand wellit.

•Do notoperate theequipment if

bystanders,animals etc are within

operatingrange of theequipment or the

general workarea.

•If devices are providedfor connecting

dustextraction/collection facilities,

ensuretheseareconnectedandused

properly.Dustcollection canreduce

dust-relatedhazards.

GeneralPersonalSafety

•Wear appropriateprotectiveequipment

w henoperating,servicing,or whenin

the operatingarea of theequipment to

help protectfromeyeand earinjury,

poisoning, burns,cuttingandcrush

injuries. Protectiveequipment suchas

safety goggles, respirators,non-slip

safety footwear, hardhat,hearing

protectionetc should be usedfor

appropriateequipment / conditions.

Other people nearby shouldalsowear

appropriatepersonalprotective

equipment. Do not wear loose clothing

or jew ellery,w hichcanbecaughtin

moving parts.Keep hair andclothing

away fromtheequipment.

•Stay alert and use common sense

whenoperatingtheequipment. Do not

over-reach.Always maintain secure

footingand balance.

•Do notuse theequipment if tired or

under the influence of drugs, alcoholor

medication.

•This equipment is notintended for use

by persons withreducedphysical,

sensory or mental capabilities.

GeneralFuel Safety

•Petrol/fuel/gasoline is extremely

flammable –keep clearof naked flames

or other ignition sources.

•Do notspill fuel.If youspill fuel,wipeit

off theequipment immediately –if fuel

gets on your clothing,changeclothing.

•Do NOT smoke near fuelor w hen

refuelling.

•Always shutoff theenginebefore

refuelling.

•Do NOT refuela hotengine.

•Open the fuelcapcarefully toallow any

pressurebuild-upin thetank torelease

slowly.

•Always refuelinw ellventilatedareas.

•Always checkfor fuelleakage.If fuel

leakage is found,donot startorrun the

engine until all leaks arefixed.

GeneralCarbon-MonoxideSafety

•Using a combustion engine indoors

CANKILL IN MINUTES. Engine

exhaustcontains carbon-monoxide–a

poisonyou cannotsmell or see.

•Use combustionengines OUTSIDE

only, andfar away fromw indows, doors

and vents.

General Equipment Use and Care

•The equipment is designedfor

domestic useonly.

•Handle the equipment safely and

carefully.

•Beforeuse,inspecttheequipment for

misalignment or binding of moving

parts,loosecomponents,damage or

any other condition that may affect its

operation.If damaged, havethe

equipment repairedby an authorised

service centre or technicianbefore use.

•Prevent unintentional startingof the

equipment - ensureequipment and

power switchesare in theOFF position

before connectingor moving

equipment. Do not carry equipment

withhands or fingers touchingany

controls. Remove any tools or other

items that are nota part of the

equipment fromit beforestartingor

switchingon.

•Do notforcetheequipment. Use the

correctequipmentfor your application.

Equipment willperformbetter and be

safer whenusedwithin its designand

usageparameters.

•Use the equipment andaccessories

etc.in accordancewiththese

instructions,consideringworking

conditionsand the worktobe

performed.Using the equipment for

operations differentfromthose

intended couldresultin hazardous

situations.

•Always keepequipment components

(engines,hoses,handles,controls,

frames, housings,guards etc) and

accessories(cuttingtools,nozzles,bits

etc) properly maintained. Keep the

equipment cleanand, where

applicable, properly lubricated.

•Storethe equipment out of reachof

childrenor untrainedpersons.To avoid

burns or firehazards, letthe equipment

cool completely beforetransportingor

storing.Never place or storethe

equipment near flammable materials,

combustible gases or liquids etc.

•The equipment is not weather-proof,

and shouldnot be storedin direct

sunlight, at high ambient temperatures

orlocations thatare damp or humid.

•Do notclean equipment withsolvents,

flammable liquids or harshabrasives.

•For specific equipmentsafety useand

care,seeEquipment Safety.

12V/24VHeavy-DutyBattery Charger

GeneralElectricalSafety

•Inspectelectricalequipment, extension

cords,powerbars, andelectricalfittings

for damage or w ear before each use.

Repair or replacedamaged equipment

immediately.

•Ensure all power sources conformto

equipment voltagerequirements and

aredisconnectedbeforeconnectingor

disconnectingequipment.

•When w iringelectrically powered

equipment, follow allelectricaland

safety codes.

•Wherever possible,use aresidual

currentdevice(RCD).

•High voltage/ high currentpow er lines

may be present.Useextreme caution

to avoidcontactor interferencewith

power lines. Electricalshockcan be

fatal.

GeneralElectricalSafety

•Electrically groundedequipment must

havean approvedcordandplug and be

connectedtoa groundedelectrical

outlet.

•Do NOT bypass theON/OFF sw itch

and operateequipment by connecting

and disconnectingtheelectricalcord.

•Do NOT useequipment that has

exposedwiring,damagedswitches,

covers or guards.

•Do NOT useelectricalequipment in wet

conditions or in damp locations.

•Do NOT useelectricalcords tolift,

move or carry equipment.

•Do NOT coil or knot electricalcords,

and ensureelectricalcords arenottrip

hazards.

GeneralServiceInformation

•The equipment must be servicedor

repairedat authorisedservicecentres

by qualified personnelonly.

•Replacement parts must beoriginal

equipment manufacturer (OEM) to

ensureequipment safety is maintained.

•Do NOT attempt any maintenance or

repair worknot describedinthis

manual.

•After use,theequipment and

components may still behot –allow the

equipment to cooland disconnect

sparkplugs and/or electricalpow er

sources and/orbatteries fromitbefore

making adjustments, changing

accessoriesor performingrepair or

maintenance.

•Do NOT make adjustments whilethe

equipment is running.

•Performservicerelatedactivities in

suitable conditions,such as a

workshop.

•Replace w orn,damagedor missing

warning/safety labels immediately.

12V/24VHeavy-DutyBattery Charger

Equipment Safety

•Locate the charger as far away from the battery as the charger cables allow.

•Do NOT charge a frozen battery. If battery fluid (electrolyte) is frozen, place the battery in a warm area to

thaw before charging.

•Do NOT allow battery acid to contact the charger or any of its components.

•Do NOT place a battery on top of the charger.

•Do NOT place the charger directly above a battery being charged. Gases from the battery may corrode

and damage the charger.

•Do NOT allow the battery terminal clamps to touch at any time when the charger is energized.

•Do NOT start a vehicle engine with the charger connected to the vehicle battery.

•Boat batteries should be removed from the boat and charged on land.

•Always select the correct voltage of the battery being charged. Do NOT charger a battery using a

different voltage to the battery rating.

•Always follow battery manufacturer instructions for battery charging.

•Always follow vehicle manufacturer instructions for in-vehicle battery charging or jump-starting.

•When using the equipment, basic safety precautions detailed here must always be followed to reduce

the risk of fire, electric shock, personal injury and material damage.

•To provide a good electrical connection, ensure that the battery terminals and battery charging clamps

are clean before connecting them.

•Ensure the electrical supply conforms to the equipment requirements.

•To reduce risk of electric shock, disconnect the equipment from the electrical supply before connecting

batteries, cleaning etc.

•Do not use an extension cord unless necessary. Use of an improper extension cord could result in fire or

electric shock. If an extension cord must be used, make sure that:

•The extension cord socket is compatible with the charger plug.

•The extension cord is properly wired and in good condition.

•The extension cord wire gauge is suitable for the charger current rating.

12V/24VHeavy-DutyBattery Charger 
E&OE ©2017 Rossi 5 
Table of Contents 
Safety................................................................................................................................................... 2 
Equipment Safety............................................................................................................................... 4 
Parts and Functions Identification................................................................................................... 6 
Wheel Assembly................................................................................................................................6
Operation............................................................................................................................................ 7 
Charging Currents and Times .............................................................................................................7
Using Charging Cables ......................................................................................................................7
Charging a Battery.............................................................................................................................8
Jump-Starting....................................................................................................................................8
Maintenance andTroubleshooting.................................................................................................. 9 
Replacing the Fuse............................................................................................................................9
Troubleshooting.................................................................................................................................9 
Specifications..................................................................................................................................... 9 
 

12V/24VHeavy-DutyBattery Charger

Parts and Functions Identification

Note: Spare fuses may be supplied.

No.

Name

No.

Name

1

ChargerBody

9

Fuse

2

POSITIVE (+) ChargingCableand Clamp

10

Output Current Meter (Digital or Analogue)

3

NEGATIVE (-) ChargingCableand Clamp

11

Charge RateSwitch

4

Wheel (2)

12

ChargeMode Switch

5

Axle

13

ChargerMode Switch

6

Washer(4)

14

ON / OFF Switch

7

Circlip (4)

15

+12V Output Cable Terminal

8

Wheel Cap (2)

16

+24V Output Cable Terminal

Wheel Assembly

1. Slide the axle through the hole in the lower-rear part of the

charger body.

2. On each side of the axle, place a circlip in the inner groove (circlip

pliers may be required), followed by a washer.

3. On each side of the axle, place a wheel, followed by a washer.

4. On each side of the axle, place a circlip in the outer groove (circlip

pliers may be required), followed by a wheel cap.

1

11

9

4

3

12

2

10

13

14

15

16

5

8

6

7

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12V/24VHeavy-DutyBattery Charger

Operation

Substances used in batteries and gases or vapours produced when charging

may be extremely flammable –keep clear of naked flames or other ignition

sources. • Correct battery polarity MUST be followed. Incorrect polarity may present an explosion or fire

hazard. • Do NOT attempt to charge a frozen battery. • Do NOT connect to or charge the battery of a running

engine. • Failure to correctly follow the vehicle manufacturer instructions for in-vehicle charging or

jump-starting may damage vehicle electronics. • Do NOT connect the battery connect clamps to any part

of the fuel system or sensitive electrical components. • Position all charger cables so they cannot contact

conductive parts of the vehicle (except the battery terminals), be pinched or caught etc. • Always select the

correct voltage of the battery being charged. Do NOT charger a battery using a different voltage to the

battery rating. • Always follow battery manufacturer instructions for battery charging. • If applicable, before

charging, remove any battery cell ventilation caps and check that the cell electrolyte level is adequate. After

charging, check electrolyte level and re-install battery cell ventilation caps. • Do NOT use "boost" charge

mode for longer than necessary to "revive" the battery.

The battery charger is suitable for charging a range of high-capacity (120 to 320Ah) 12V and 24V lead-acid

batteries. The charger features a logic controlled charging program that monitors battery charge and

switches modes automatically to ensure the battery charge is as close to 100% of the original capacity as

possible.

The charger can restore almost completely discharged batteries using the "boost" charge mode. This mode

continuously charges at 5A (it does not deviate) and, therefore, cannot be used for the full charge cycle, but

to "revive" the battery sufficiently so it can be charged normally. In "normal" charge mode, it is possible to

leave the charger connected to a battery indefinitely, in which case it will maintain battery charge as required.

Charging Currents and Times

The battery charger does NOT automatically switch off when a battery is charged. It MUST

be switched off manually. Charging must be monitored often to prevent overcharging of the

battery. Over-charging a battery could cause personal injury and/or property damage.

The unit has various charge output currents depending on selections:

Selection

BT-280

BT-750

MIN + 1

26A / 0.65kW

31A / 0.80kW

MIN + 2

31A / 0.80kW

36A / 1.30kW

BOOST + 1

33A / 1.00kW

43A / 1.60kW

BOOST + 2

36A / 1.30kW

50A / 2.00kW

Use the following formula to calculate the approximate charge time for a battery:

Charge Time = Battery Capacity (Ah) / Charge Current (A) x Discharge Level (%)

For example, a 200Ah battery being charged at 50A from a 70% discharged state would be:

200 / 50 x 0.7 = 2.8 hours (168 minutes)

For example, a 320Ah battery being charged at 36A from a 40% discharged state would be:

320 / 36 x 0.4 = 3.6 hours (213 minutes)

Using Charging Cables

The charging (output) cables are colour-coded for polarity –RED = POSITIVE and BLACK = NEGATIVE. To

use, squeeze the clamp toopen the jaw, then place the jaw over the battery terminal and release the clamp.

Ensure that the clamp is firmly attached to the battery terminal.

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12V/24VHeavy-DutyBattery Charger

Charging a Battery

Do NOT use "Boost" charge mode for longer than necessary to "revive" the battery. A

battery may be permanently damaged if over-charged. Calculate charge time before

charging. • For batteries in vehicles, consult the vehicle manufacturer instructions for connecting a charger to

the battery. Failure to correctly follow the vehicle manufacturer instructions for in-vehicle charging

may damage vehicle electronics. • For batteries connected in series, consult a automotive electrician for

advice on how to charge the batteries.

1. Connect the POSITIVE charging cable to the required output connection terminal

(+12V or +24V) on the charger. To attach the cable, remove (rotate left) the

terminal nut (A), then place the "eye" of the cable connector (B) onto the terminal

screw (C). Re-install the terminal nut (rotate right) and tighten firmly by hand.

2. Connect the POSITIVE clamp to the battery POSITIVE terminal, the connect the

NEGATIVE clamp to the battery NEGATIVE terminal.

3. Connect the charger to a 240VAC electrical supply and switch the supply ON.

4. Switch the battery charger ON at the ON / OFF switch.

5. Set the Charge Mode switch to MIN for "normal" battery charging. Set to BOOST if the connected

battery is discharged to the point that normal charging cannot be used.

6. Set the Charge Rate switch to 1for batteries under 200Ah, or 2for batteries over 200Ah.

7. Set the Charger Mode switch to .

To stop charging:

1. Switch the battery charger OFF at the ON / OFF switch.

2. Switch the electrical supply to the charger OFF.

3. Remove the clamp from the NEGATIVE terminal, then remove the clamp from the POSITIVE terminal.

Jump-Starting

Consult the vehicle manufacturer instructions for jump-starting. Failure to correctly follow the

vehicle manufacturer instructions for jump-starting may damage vehicle electronics.

1. Connect the POSITIVE charging cable to the required output connection terminal (+12V or +24V) on the

charger.

2. Connect the POSITIVE clamp to the battery POSITIVE terminal, the connect the NEGATIVE clamp to

the battery NEGATIVE terminal.

3. Connect the charger to a 240VAC electrical supply and switch the supply ON.

4. Switch the battery charger ON at the ON / OFF switch.

5. Set the Charge Mode switch to BOOST.

6. Set the Charge Rate switch to 2.

7. Set the Charger Mode switch to .

8. Start the engine. Do NOT crank the engine continuously for more than 3 seconds. If the engine fails to

start, set the Charger Mode switch to , and charge the battery for a minimum 15 minutes.

9. Switch the battery charger OFF at the ON / OFF switch, then switch the 240VAC electrical supply to the

charger OFF.

10. Disconnect the charging cables –NEGATIVE first, then POSTIVE.

A

B

C

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12V/24VHeavy-DutyBattery Charger

Maintenance and Troubleshooting

Do not use the charger if any of the electrical cords or terminal clamps have been damaged

in any way. If the power supply cord is damaged, it must be replaced by the manufacturer,

its service agent or qualified person to avoid a hazard. • Some activities described may be beyond the scope

of some users. For procedures that you are not comfortable with or have the tools, knowledge or experience

for, or if problems persist after following all suggested actions, contact a service centre or qualified

technician.

Follow these steps below to maintain the charger in optimum condition:

•After each use, clean the battery charger clamps - be sure to remove any battery fluid as this will cause

corrosion of the copper material.

•Clean the outside case of the charger with a soft cloth and, if necessary, mild soap solution.

•Keep the charger cords loosely coiled during storage to prevent damage to them.

Replacing the Fuse

1. Lift the fuse cover from the charger to expose the fuse and

terminals (A).

2. Using a suitable spanner, loosen the terminal nuts (B), then

remove the blown fuse.

3. Insert the new fuse. Note that the fuse "blades" (C) are rated at

50A, therefore, use 2 for a 100A fuse.

4. Firmly tighten the terminal nuts, then re-install the fuse cover.

Troubleshooting

The following information may assist in identifying a problem and rectifying it.

Battery not being charged

Possible Fault

Action

Poor electrical connectiontobattery

Ensure that thebattery connectioncables tothe battery aresecure.Checkthat the battery

terminals/clamps areclean and notcorroded,toprovidea good electricalconnection.

DCoutput fuseblown

checkto seeif the fuse"blade"isbroken. If it is, replacethe fuse.Usereplacementfuses of

the same rating.

Specifications

Electrical Requirements

240VAC / 50Hz.

Battery Compatibility

12V / 24V Lead-Acid types.

Output Current

See here.

B

A

C

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12V/24VHeavy-DutyBattery Charger

Some experts believe that the incorrect or prolonged use of almost any

product may cause seriousinjury or death.To helpreduce your risk of

seriousinjury or death,refer to the information below. For more information,

see www.datastreamserver.com/safety

Consult all documentation, packagingand product

labelling beforeuse.Note that some products

featuredocumentationavailable online. It is

recommended to print and retainthe

documentation.

Beforeeachuse,checktheproduct for

loose/broken/damaged/missing parts,w earor leaks

(if applicable).Never usea productwith

loose/broken/damaged/missing parts,wearor

leaks.

Products must be inspectedandserviced(if

applicable) by a qualifiedtechnicianevery 6

months. This is basedon averageresidentialuse

by persons of averagesizeandstrength,andona

property of averagemetropolitansize.Use beyond

theserecommendations may requiremore frequent

inspections/servicing.

Ensure that all users of theproducthavecompleted

a suitable industry recognisedtrainingcourse

beforebeingallowedaccess totheproduct.

The producthasbeen supplied by a generalmerchandiseretailer that

may not be familiar withyour specificapplicationor description of

application. Be sureto attain third-party approvalfromaqualified

specialist for your applicationbefore use,regardless of any assurances

fromthe retailer or its representatives.

This product is not intended for use where fail-safeoperation is

required.As w ithany product(forexample,automobile, computer,

toaster), thereis the possibility of technicalissues thatmay requirethe

repair or replacementof parts, or the product itself. If the possibility of

suchfailureandthe associatedtime it may take to rectify couldinany

way inconveniencetheuser, business or employee,or financially affect

the user,business or employee,then the productis not suitable for

your requirements.This product is not intended for use where incorrect

operationor a failureof anykind, including but not limited to, a

condition requiringproduct return,replacement,parts replacement or

serviceby atechnicianmay causefinancialloss,loss of employee time

or an inconvenience requiringcompensation.

If this producthas been purchasedinerror w henconsideringthe

information presentedhere, contact theretailer directly for details of

their returns policy,if required.

diagrams or images may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying, scanning or recording, or any information storage and retrieval system,

without express permission or consent from the publisher.

Rossi BT-280 User manual

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