TurboStart SMARTCHARGER CHG25A User manual
SMARTprocessor Controlled Multi-Stage
12V/14V/16V Charger
P/N CHG25A / CHG25AE
USER GUIDE
TurboStart SMARTCHARGER
USER GUIDE
About TurboStart
TurboStart designs and produces performance energy solutions for performance vehicles. Whether it’s a daily driven
hot rod, custom street rod, or an all out on road or off road race vehicle, TurboStart has the battery, charger, and
accessories to best solve your vehicles energy needs.
Trademarks
Trademarks, registered trademarks, and product names are the property of their respective owners and are used herein
for identification purposes only.
Notice of Copyright
SMARTCHARGER User Guide © January 2006-2016 by TurboStart. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, TurboStart:
(A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY, OR SUITABILITY OF ANY TECHNICAL OR OTHER
INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL, OR
INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL
BE ENTIRELY AT THE USER’S RISK.
The following conventions are used in this guide.
WARNING
Warnings identify conditions that could result in personal injury or loss of life.
CAUTION
Cautions identify conditions or practices that could result in damage to the charger or battery.
*Important*: These notes describe an important item that you must pay attention to.
TurboStart SMARTCHARGER USER GUIDE
Chapter 1, Safety and Precautions................................................p. 1-2
Chapter 1 covers safety guidelines and precautions for using your SMARTCHARGER.
Chapter 2, Features and Functions.....................................................p. 3-4
Chapter 2 explains the features, functions, specs, and benefits of the SMARTCHARGER.
Chapter 3, Operations ..............................................................................p. 5-7
Chapter 3 explains the switches and indicators on the front panel of your
SMARTCHARGER, including step by step instructions to correctly charge a performance battery.
Chapter 4, Troubleshooting.......................................................................p. 8
Chapter 4 will help identify and correct common issues that may occur with your
SMARTCHARGER.
FAQs .................................................................................................................p. 9-10
Warranty ................................................................................................................p. 11
Customer Info..........................................................................................................p. 12
Contact Information.................................................................................................p. 12
Contents
Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in
which the battery is installed.
1) Make sure the area around the battery is well ventilated.
2) Never smoke or allow a spark or flame near the battery(ies).
3) Use caution to reduce the risk of dropping a metal tool on the battery. It could spark or short circuit the battery or other
electrical parts and thereby cause an explosion.
4) Remove all metal items, like rings, bracelets, and watches when working with lead-acid batteries. Lead-acid batteries
produce a short circuit current high enough to cause a severe burn.
5) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
6) Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries.
7) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood
it with running cold water for at least twenty minutes and get medical attention immediately.
8) If you need to remove a battery, always remove the ground terminal from the battery first. Make sure all accessories are off
to minimize the potential of a spark.
9) Someone should be in the range of your voice or close enough to come to your aid when working with a lead-acid battery.
10) Do not attempt to remove the vent covers on sealed lead-acid batteries such as the TurboStart 16V AGM battery. Sealed
batteries operate on a slight positive cell pressure. Venting this pressure will ruin the battery.
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TurboStart SMARTCHARGER USER GUIDE
Chapter 1
Precautions Working With
Lead-Acid Batteries
SMARTCHARGER generate a low DC voltage and high DC current to the battery being charged.
Improper operation of the charger or misuse of the charger may cause damage to the charger or create
hazardous conditions for the user.
WARNING: Explosion hazard
SMARTCHARGER are designed to charge 12V/14V/16V lead-acid batteries of all types. Do not attempt to use with
batteries with voltages not matching the chargers specified voltage.
• Donotusethisproductwherethereareflammablefumesorgases.
• Donotusethisproductinanenclosurecontaininglead-acidbatteries.Thesebatteriesventexplosivehydrogengas,whichcanbe
ignited by sparks from electrical connections.
• Neverattempttochargeafrozenbattery.
• DonotconnectDCclampstothecarburetor,fuellines,orsheetmetalbodyparts.
WARNING: Shock hazard. Keep away from children.
• Donotexposechargertowater/rainortemperaturesover104°F(40°C).
• Donotopenthecharger.Therearenouserserviceablepartsinsidetheunit.ForserviceseetheReturnspolicyinthebackofthisguide.
• BesureACandDCcordsarenotpinchedorotherwisedamagedbyhoods,doors,orothermovingenginecomponents.
• Observebatterypolarity.
IMPORTANT: If this charger is to be used with a portable generator, it should be equipped with automatic voltage regulation to
ensure consistent output of the product.
WARNING: Heated surface-Ensure at least 2” (5 cm) air space is maintained on all sides of the charger.
CAUTION
Anextension cord should not be used unless absolutely necessary. Do not use this product with an ungrounded extension
cord. Use of an undersized extension cord will adversely affect the output of the product and could prove to be dangerous. If
anextension cord must be used, make sure that pins on the plug of the extension cord are the same number, size and shape
asthose of the plug on the charger. TurboStart Batteries recommend a minimum of a 16AWG cord for lengths up to 50’ and a
minimum of a 14AWG cord for lengths up to 100’. We do not recommend cords over 100’.
TurboStart SMARTCHARGER USER GUIDE
Chapter 1
Important Safety
Instructions
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TurboStart SMARTCHARGER USER GUIDE
Chapter 2
Features of the TurboStart
SMARTCHARGER
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SMARTCHARGERS are a group of advanced battery chargers designed specifically for high performance
12V/14V/16V sealed lead-acid batteries. SMARTCHARGERS combine the reliability of a HFM rectified
assemblywithaSMARTprocessor controlboard to create a battery charger that can rapidly and safely recharge
12V/14V/16V maintenance free, deep cycle, gel-cell, and AGM (Absorbed Glass Mat) batteries in several sizes.
Multi-Stage Charging
Smart charging is the brains behind the chargers multi-step system. During the Stage 1, “Bulk” charging, the current is fixed and
the voltage is allowed to float. During this stage, 80% of the battery’s capacity is restored.
When the battery’s cell voltage is up to the correct level Stage 2, “Absorption” charging, is applied. In Stage 2 the battery
will be charged to 100%. During Stage 3, “Float” charging, the voltage and current are reduced to a level that will
maintain the battery indefinitely.
SMARTprocessor are used to tightly control the entire process. This is the same technique that battery manufacturers
recommend and use in the production of new batteries and it is the fastest and safest technique for battery charging.
Compatible With All 12V, 14V &16V AGM and Gel-Cell Batteries
SMARTCHARGERS are compatible with most LEAD ACID rechargeable Batteries Including AGM, deep cycle, and gel-cell.
Lead-acidbatterieshavedifferentchargingrequirementsbasedontheirspecificdesign.Overchargingwillreducethelifeofanybatteryassealed
valve regulated batteries are especially sensitive to high charging voltages and overcharging.
Overcharging an AGM or gel-cell battery will cause permanent damage.
Output Display
The SMARTCHARGER features a digital output display allowing the user to monitor the volt and amps.
Voltage Monitoring
Thevoltageismeasured every five minutesatthebattery’sterminalsbytheon-board SMARTprocessor andthisinformation
is used by the SMARTCHARGER to control the battery charging for optimum charging performance.
Automatic Computer Analysis/Auto Shutdown
Themicroprocessors willanalyzethebattery whenconnected. Ifthebattery’svoltageis below4Vorthe batterywillnot come uptothe correct
voltage in a ten-hour period the charger will automatically shut off.
Internal Cooling Fan
A cooling fan automatically operates during charging to keep the circuit and other internal components at a constant
safe temperature.
Physical Specifications
- Dimensions ................................ 8 5/8” W x 7” H x 11 1/8” D
- Weight ....................................... 24 lbs (10.87 kg)
- AC Input Connections ................... 5.0’ (1.5 m) AWG 16
- DC Output Connections ................ 6.0’ (1.8 m) AWG 10
Electrical Specifications
12V 14V 16V
- Absorption Voltage ...................... 14.40 VDC ..... 16.80 VDC ..... 19.20 VDC
- Float Voltage at no Load .............. 13.56 VDC ..... 15.82 VDC ..... 18.08 VDC
- Maximum Output Voltage ............. 14.40 VDC ..... 16.80 VDC ..... 19.20 VDC
AC Input Specifications
- AC Input Voltage ......................... 120VAC, 50/60Hz or 230VAC, 50/60Hz
- AC Input Current .......................... 10A RMS fuse protected
Important: Specifications are subject to change without notice.
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TurboStart SMARTCHARGER USER GUIDE
Chapter 2
Physical Specifications
TurboStart SMARTCHARGER USER GUIDE
Chapter 3
Battery Charging
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SMARTCHARGERS charge batteries in what is known as the multi-stage charging sequence. The charging
voltage delivered to the battery depends on the battery’s depth of discharge.
The 3 stages are:
•Stage1-Bulk
•Stage2-Absorption/Equalization
•Stage3-Float
Stage 1 / Bulk Charge
InStage 1 /Bulk charging the SMARTCHARGERdeliversitsfull-ratedoutputcurrent.Thisconstantcurrentisdelivered
to the batteries until the battery voltage approaches its absorption voltage, either 2.5V per cell or 2.375V per cell depending on
battery type selected. Stage 1 / bulk charge restores about 75% of the battery’s charge and this stage is completed very quickly
unless the battery is deeply discharged. During this stage the charge rate current on the ammeter should close to the charge rate
selected on the front panel switch.
Stage 2 / Absorption Charge
DuringtheStage2/Absorptionchargingthe chargingvoltageisheldconstantnearthegassingvoltage,and thechargingcurrent
is allowed to diminish as the battery comes up to 100% charge. Complex algorithms considering the time, voltage level, and
charging current determine when the charger exits this stage and goes to the final stage, Stage 3 / Float charging. The length of
time of this stage depends on the battery and is not fixed.
Stage 3 / Float Charge
Stage 3 / Float charging is a maintenance phase in which the output voltage of the charger is reduced to a lower level, typically
about 2.26 V per cell to maintain the battery’s charge without losing electrolyte through gassing. In the Stage 3 / float charge,
the charger will initiate a new charge cycle if:
•ACpowerisdisconnectedandreconnected
•ThecurrentdemandontheSMARTCHARGER exceeds the battery recharge current setting.
Figure B-1 Three-stage charging profile
VOL TAGE
CURR EN T
PERFORMANCE CURVE
BULK CHARGE ABSORPTION CHARGE
CONSTANT CURRENT CONSTANT VOLTAGE
FLOAT CHARGE
Volts Per Cell
Amperage
Charge Start Charge Complete
TIME
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TurboStart SMARTCHARGER USER GUIDE
Chapter 3
Operation
Charging Lead-Acid Batteries
WARNING: Before you start to charge batteries read the “Important Safety Instructions” on page and take all safety
precautions when working with batteries.
SMARTCHARGER have been designed to provide fully automatic recharge most 12V/14V/16V AGM and gel-cell batteries.
To charge your 12V, 14V or 16V battery:
1) If possible, disconnectallloads fromthe battery,by removing batterycables,opening a disconnectswitch,or switchingloadsoff.
CAUTION!
Although this is best, in a racing environment this may not be possible. Supplemental loads such as an electric water
pump or cooling fans may be operated while charging during stage one. Please note though that supplemental loads
will reduce the amount of amperage available to the battery. The charger detects that a battery is fully charged when its
charging current drops below a preset limit in a specific elapsed time. The presence of electrical loads on the battery will
interfere with this process. Therefore when the charger is in stage two-absorption charging it is necessary for the battery
tobe isolated from loads.
The SMARTCHARGER is in Stage 2 when the charge rate is declining.
2) Select the correct battery voltage.
3) Select the correct charging rate.(TurboStart 16V AGM battery should be charged at 15A when at the shop or 25A for rapid
charging at the track.)
4) Connect the red positive (+) clip of the charger cables to the positive (+) terminal of the vehicle battery.
5) Connecttheblacknegative(–)clipof the chargercablesto asolidchassisground.Ifthisisnot possible,connectittothenegative
(–) battery terminal.
6) Flip the power switch on the front panel to ON.
The SMARTprocessor will analyze the battery and then after a short delay, the “Charging Status” indicator on
the front panel will illuminate beginning the three-stage charging sequence. During charging, the charging current can be
reset to a different charge rate if necessary.
CAUTION:Do not change the voltage type during charging. Use the correct battery type at all times.
DuringStage 1,bulkcharging,the amperagewillbegin at20A. DuringStage2,absorption charging,the amperagewill
start to fall to zero as the battery comes up to 100%. After the charging process is completed, the “Charging” indicator
light will go out and the Float Charge indicator will come on. During Stage 3, Float charging, the cooling fan inside the
charger will stop and the battery can be left in this stage indefinitely.
*Note that the charger will automatically restart the charging sequence if the charge current rises above a factory preset threshold.
7) When complete, flip the power switch to OFF.
8) Remove the black negative (–) clip and the red positive (+) clip from the vehicle’s battery terminals.
TurboStart SMARTCHARGER USER GUIDE
Chapter 3
Switches and Indicators
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1) Volt & AMP Output Display: (Selectable) Indicates either voltage or amperage output of the charger.
During Stage 1, “Bulk Charging”, amperage will display the selected charge rate. During Stage 2, “Absorption
Charging”, this rate will naturally fall to zero as the battery percent of change nears 100%. In Stage 3, “Float
Charging”, the indicator will read close to zero.
2) Display Mode: Allows the user to select displaying voltage and amperage. LED indicators illuminate when
either voltage or amperage is selected.
3) Voltage Select:Allows the user to select the appropriate battery voltage. LED indicators illuminate for either
12V(6cell), 14V(7cell), or 16V(8cell) batteries respectively.
4) Charging Rate:Select 5A, 15A, or 25A as base rate for Stage 1 or bulk charging. In general, the rate should
match the size of the battery.
5) Power Switch: Illuminates when the input AC power is applied.
6) Charging Indicator: Illuminates when the charger is in stage one bulk charging or stage two absorption charging.
7) Float Charge Indicator:Illuminates when the charger is in stage three or float charge mode.
8) Error Indicator:Illuminates when the battery cannot be completely charged in a 10 hour period at the selected
charge rate. Switch the charger OFF and remove the battery connections. Insure the battery polarity is correct, and if so,
replace battery.
9) Fuse Holder:Contains a 10A fuse in case of overload.
10) AC Cord:Grounded 3-pin 110V(220V for “E” model) cord for use with grounded outlets only.
11) Battery Clamps and Cord: Allow for connection to the battery.
CAUTION: It is important to select the correct battery type.
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TurboStart SMARTCHARGER USER GUIDE
Chapter 4
Troubleshooting
Please read this chapter before calling Customer Service. If you cannot solve the problem with the
SMARTCHARGER, record the information asked for on “Information About Your System” on the back page
and then call Customer Service. Thank You.
WARNING: Electric shock hazard
Do not disassemble the SMARTCHARGER. The SMARTCHARGER does not contain any internal user
serviceable parts and attempting to service the unit yourself could result in electrical shock or burn.
•PowerlightdoesnotcomeonwhenthepowerswitchisflippedON:
- Check fuse.
- Check cord and input power.
•VoltageLEDwillnotilluminatefor12V,14Vor16V:
- The battery is not connected.
- The battery is below 4.0V.
•Chargeratedoesnotcomeuptotheselectedchargerateinitially:
- The battery charger has already moved into stage two charging.
- Input voltage is below 120VAC.
- The battery may be defective and resisting the charge current.
•LCDDisplayErrorCodes:
- F01: The battery may be damaged and unable to accept charge.
- F02: The battery did not reach the full voltage after 48 hours charge time.
- F03: The battery is connected to the charger backwards.
- F04: The charger is overheated. If the temperature exceeds 185ºF/85ºC, the charger will stop working for
30 minutes and restart automatically.
- F05: The wrong voltage selected for the battery being charged.
•“Error”indicatorisilluminated:
- This illuminates when the battery cannot be completely charged in a 10 hour period at the selected charge rate
To reset this error, switch the battery charger OFF and remove the battery connections. Insure the battery polarity is correct. If
you are charging a large battery at the 5A rate, try a higher charge rate. If the error persists, replace the battery.
TurboStart SMARTCHARGER USER GUIDE
FAQ’s
9
Can I change the clamps on the charger with quick disconnects?
Yes. We recommend soldering all electrical connections where possible.
Can I run my electric water pump and cooling fan while charging?
Yes with a word of caution. There are two issues. First the charger will only provide 25A maximum charge current. Any
amperage being consumed by extra electrical loads (ie. electric water pumps, etc.) will take away from the amperage
available for battery charging. The battery charge time will be increased. In addition, the battery charger monitors the
battery voltage and time to determine when the battery is at 100% charge. Extra electrical loads on the system will
give the charger false information and therefore will prevent the charger from properly completing stage two.
Second, some electrical items can be damaged by high voltages. Data loggers, computers, and other items may lose
data or be seriously damaged if subjected to the 19.0~20.0VDC of charging voltage. We do not recommend retrieving
this information while charging. If in doubt about a particular component, consult with its manufacturer concerning
its maximum input voltage.
CAUTION: Data loggers, computers of all sorts, and light bulbs may be damaged by the 19.0~20.0VDC of
input voltage during charging. Do not operate these items while charging. We recommend disconnecting the battery
from the system while charging.
Can I run this charger from a portable generator?
Yes with a word of caution. Since the output of the battery charger is directly proportional with the input voltage, we
recommend portable generators with automatic voltage regulation. The SMARTCHARGER is calibrated at the
factory assuming 120VAC, 60Hz or 230VAC, 60Hz. Deviations from these voltages will cause deviations in the output
voltage and overall performance.
How many batteries can I recharge at one time with the SMARTCHARGER?
This depends on the size of the batteries. All batteries in the bank must be of the same type and size. In addition,
the SMARTCHARGER is expecting the battery bank to be at full charge in 10hrs or less. Therefore the size of the
batteries and their depth of discharge will play a role in the answer here. If you were charging all Turbo Start 16V AGM
batteries with a size of 50Ah at 100% discharged, you can charge up to four in parallel in 10hrs.
TurboStart SMARTCHARGER USER GUIDE
FAQ’s
Calculating External Battery Charging Time
Charging time will depend on the amp-hour capacity of the battery and it’s DOD. DOD, short for the Depth
of Discharge, is used to describe how deeply the battery is discharged. If a battery is 100% fully charged, it
means the DOD of this battery is 0%, If the battery has delivered 30% of its energy, there is 70% energy
reserved, then the DOD of this battery is 30%. And if a battery is 100% empty, the DOD of this battery is
100%. DOD always can be treated as how much energy that the battery delivered. The following equation
calculates an approximate charging time:
Charging Time = CAP x DOD
CC x 80% where:
Charging Time = Battery recharge time in hours
CAP = Battery capacity in amp-hours
DOD = Battery depth of discharge in percent.
A fully discharged battery has 100% DOD.
CC = Charge current. The rated current output of the charger in amps.
80% = Typical charging efficiency for lead-acid batteries.
Example:
A TurboStart 16V AGM battery rated at 50 amp-hours is 60% discharged, that is, it has a DOD
= 60%. Charging time with an SMARTCHARGER 15A unit is calculated as follows:
Charging time = 50Ah x 60% = 1.3 hours (1 hours, 21 minutes)
25A x 80%
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Warranty
We take great pride in our quality, value and performance and believe that this product should offer you trouble free operation throughout
its lifetime providing you take care to follow the simple instructions in the product documentation.
If you experience any problems with your product, please read the warranty details listed below carefully.
Limited Warranty
TurboStart provides a one year warranty from the date of purchase, to the original purchaser. This warranty covers manufacturing defects
in material and workmanship only.
TurboStart does not cover damage or failure caused by abuse, misuse, faulty installation, improper maintenance, or any attempted
repairs not carried out by TurboStart.
There will be no obligations or liability on the part of TurboStart for consequential damages arising from the use of the product or any
indirect damages with respect to loss of property, revenue, or costs for removal, installation, or reinstallation.
For warranty service, the product must be reported to TurboStart to receive a unique RGA number(return goods authorization) and at
that time you will be advised of where to send the faulty product.
All shipping charges for returns should be prepaid. If the requested repairs or service are within the terms of this warranty then the
item will be returned to you on completion without any charge. The unit must be in its original packaging with any original accessories.
TurboStart will not be responsible or accept any liabilities for any loss or damage to additional items which are sent with returned product.
If the product is not covered under the terms of this warranty Turbo Start will advise you of the costs to carry out any repairs necessary
and the unit will be shipped to you on receipt of payment for the work including the return freight charges.
Please allow 2 to 4 weeks for return of your product. Under normal circumstance we try to ensure we carry out warranty repairs within
5 working days. We cannot be held responsible for delays in shipping.
Product
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY TURBO START IN CONNECTION WITH YOUR TURBO START
PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS,
OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING
(WHETHER BY CONTRACT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER’S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR
OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT
REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER
THIS LIMITEDWARRANTY. INNOEVENT WILLXSPOWERBELIABLEFORANY SPECIAL, DIRECT,INDIRECT, INCIDENTAL ORCONSEQUENTIAL
DAMAGES, LOSSES, COSTSOREXPENSESHOWEVERARISINGWHETHERINCONTRACTINCLUDINGWITHOUTRESTRICTIONANY ECONOMIC
LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A
RESULT OF MISUSE OR ABUSE, OR THE INCORRECT OPERATION OF THE PRODUCT.
Exclusions
If this product is a consumer product, federal law does not allow an exclusion of implied warranties. To the extent you are entitled to
implied warranties under federal law, to the extent permitted by applicable law they are limited to the duration of this Limited Warranty.
Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the
limitationorexclusionofincidentalorconsequentialdamages,sothe abovelimitation(s)orexclusion(s)maynotapply toyou.ThisLimited
Warranty gives you specific legal rights. You may have other rights which may vary from state to state or province to province.
TurboStart SMARTCHARGER USER GUIDE
Warranty/Disclaimer
11
TurboStart SMARTCHARGER USER GUIDE
Customer Information
As soon as you unpack your TurboStart SMARTCHARGER, record the following information and be
sure to keep your proof of purchase.
Serial Number (on back panel)
Purchased From
Purchase Date
If you need to contact Customer Service, please record the following details before calling. This information
will help our representatives give you better service.
Battery type, brand, and voltage:
Is this used with a portable generator?
Description of the problem:
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Contact Information
TurboStart Batteries
2847 John Deere Dr. Suite 102C
Knoxville, TN 37917
Ph: (877) 324-9300 (toll free North America)
Ph: (865) 394.3565
Fax: (865) 394.6534
www.turbostart.com
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