Multi-stage Smart
Battery Chargers
SBC1205, SBC24025
THE SMART BATTERY CHARGER
The SBC1205 & SBC24025 are “set and forget” four stage chargers that automatically bring and
maintain 100% charge to Lead Acid and Calcium content batteries. Being Smart Battery Chargers,
they are controlled by a microprocessor, which is constantly checking the charging process. A
battery will last longer and charge faster when charged using the Four Stage process.
WARNING & SAFETY INSTRUCTIONS
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they are supervised
or have been instructed on how to use the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Do NOT disassemble the SBC - the internal circuitry contains hazardous voltages. Attempting to
service the unit yourself may result in electric shock or fire and will void the unit warranty.
The SBC should only be powered from an earthed mains socket outlet.
The SBC is not intended for permenant mounting into a vehicle.
Do NOT use the SBC to charge non-rechargeable batteries. Doing so may result in harm to the
user and/or damage to the SBC. Only use the SBC for charging Standard Lead Acid, Calcium
content, Gel & AGM type, 6 cell, 12V batteries.
All lead acid batteries produce harmful, explosive gases. The Battery should be mounted in a well
ventilated area, as far as possible from any ignition sources. Do NOT smoke when in the vicinity
of the battery under charge.
Battery acid is a harmful substance. Care should be taken when working with lead acid batteries,
if the acid comes into contact with your eyes or skin, immediately wash the affected area with
cold running water and seek medical assistance. Eye protection and gloves should be worn when
handling lead acid batteries.
The SBC will achieve best results when proper battery maintenance is regularly performed. This
includes but is not limited to checking water and specific gravity levels of the battery.
Warning! Check the manufacturers data for your battery and ensure that the ‘Absorption’
voltage of the profile you select does not exceed the manufacturers recommended maximum
charging voltage. If the ‘Absorption’ voltage for your battery type is too high, please select another
charging profile.
SAL.FOR.Instruction Manual.SBC1205 - DOC426 – Version 1
1
CONTENTS
Table of Contents
Page
Warnings and Safety Instructions
Contents
Specifications
Key Features
1 Installation
1. Connections
2 Operation
1. The Display Panel
2. Selecting Battery Type
3. The Charging Process
4. Indication
4.1. Charging Indicator (Orange)
4.2. Ready Indicator (Green)
4.3. Fault Indicator (Red)
3 Precautions for Operation
4 Other Info
1. Charging Time & Battery Capacity
2. Calcium Batteries
5 Two Year Warranty
Specifications
AC Input Voltage Range
Input Fusing
Output Fusing
Nominal Output Voltage
Output Voltage Range
Output Current Range
Output Power
Weight
Dimensions
Operating Temperature
Warranty
Standards
SBC1205
SBC24025
216-265V AC, 50Hz
216-265V AC, 50Hz
2A Slow Blow
2A Slow Blow
10A
5A
12V
24V
12-16.5V
24-33V
0-5A
0-2.5A
80W
80W
1.55kg
1.55kg
165x140x60mm
165x140x60mm
-5°C to +50°C
-5°C to +50°C
2 years
2 years
C-Tick, AS/NZS CISPR14-1:2003, AS/NZS 3108
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01
02
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03
03
03
04
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04
05
06
06
07
08
09
09
09
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KEY FEATURES
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1
Charges Standard, Calcium, AGM or Gel Lead Acid batteries (User Selectable via
push button switch)
Reverse polarity connection protection, charging commences after the battery
has been connected correctly
Output short circuit protection
Battery overcharge protection
Faulty battery cell detection and safe charge termination
4-Stage Charging Pattern with timeout protection
Initial self test on power up
Over temperature shut down
Latest switch mode design
Designed and manufactured in Australia for Australian conditions
Safety and EMC compliance
Light and ultra compact
Recharges batteries to 100% capacity
INSTALLATION
The charger must be placed in a well ventilated position to allow air flow to cool the
charger for greater charging efficiency. The charger is best placed on top of the air filter
if charging the battery in the vehicle. If that is not possible then find a convenient safe
place where the charger is secure and not likely to fall down.
NOTE: Never place the charger on top of the battery.
Leave the vent caps closed as modern automotive batteries have a gas recombination
design built into the cap to allow the retention of the gassed electrolyte and its return to
the battery cell. All vent caps also have a venting system to allow excessive gasses to
escape. Coin screwed cap designs also have a “manifold” venting system, which works
in the same way as a screwed vent cap.
1.1
Connections
Ensure the connections are tight and sound. Then connect the 240VAC three pin plug
to the power point and switch on the power. Then switch on the Smart Battery Charger
power switch (located on the rear panel).
Once turned ON, the charger will pause momentarily, then light up all the indicators in a
sequence so you can see that they are all functional. The cooling fan will also be run up
and tested during this sequence.
3
2
OPERATION
2.1
The Display Panel
The Display Panel features 3 Charging Status LEDs, 3 Battery type indication LEDs and 1
Selector Button as outlined above.
2.2
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Charging
Ready
Fault
Standard Lead Acid
Calcium content Lead Acid
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Gel/AGM (Default)
ORANGE LED
GREEN LED
RED LED
YELLOW LED
BLUE LED
GREEN LED
Selecting Battery Type
You will have 60 seconds from the moment the charger is turned on to make the selection.
During the selection period, the selected battery type LED will flash. Once 60 seconds
has expired, the selection is locked in for the remainder of the charging period and
the selected battery type LED will remain permanently illuminated. Should an incorrect
battery be selected, the battery charger should be turned off for approximately 10
seconds, then turned back on. The correct battery selection can now be made.
2.3
The Charging Process
The SBC has been designed to return a discharged battery to 100% charge through a
rigorous charging cycle. This charging cycle assumes that no load is connected to the
battery during charging, otherwise full charge may not be achieved. It is also possible
that the charger may determine that the charging characteristics with a load applied
4
2
OPERATION
appears like a fault and terminate the charging cycle. Small loads such as the loads
drawn by vehicle electronics with the ignition turned off do not present a problem to
normal operation. The charging cycle consists of a number of stages as described over
the page, and when completed remains in a float mode indefinitely. It is safe to leave the
battery connected to the charger as the float mode will not allow over charging whilst
maintaining the battery to a fully charged state.
If the battery remains connected to the charger and a charge cycle completes, the
charging cycle will not restart even if the battery becomes discharged by a load. Instead,
the charger will continue in float mode. The full charge cycle can only be restarted by
turning the charger off, waiting for approximately 10 seconds, then turning it back on
again.
Current
Equalise
Float
FLOAT
Voltage
Absorption
EQUALISE
BOOST
Boost
ABSORPTION
4 - Stage Charging Process
Figure 1.4.1 - 4-Stage Charging Process
2.4
Indication
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The Charging indicator (ORANGE) will indicate one of the first 3 charging stages via
a number of quick flashes, followed by an OFF period.
When the Ready indicator (GREEN) is ON, the battery has finished charging and is
now in Float mode..
If the Fault indicator (RED) is flashing, a fault has caused the charging process to
terminate. The number of quick flashes, followed by a longer OFF period indicates
the nature of the fault. The fault indication will be reset when the charger is switched
OFF.
5
2
OPERATION
2.4.1 Charging indicator (Orange)
This indicator is used during the first three stages of charging (Boost, Absorption and
Equalise), and flashes at different rates to indicate the charging mode.
Boost Mode: Orange indicator ON-single flash. This mode delivers the bulk charge to the
battery by delivering maximum constant current. This stage is time limited to cater for a
fully discharged 40Ah battery, however the time taken in this mode does greatly depend
on the condition and state of charge of the battery.
Absorption Mode: Orange indicator ON-double flash.
This mode must be finished before Equalise can take place. The charger maintains
constant charging voltage, while the current reduces. This voltage is close to the gassing
voltage of the electrolyte.
Equalise Mode: Orange indicator ON – triple flash.
This mode brings the battery to full charge. A higher voltage is applied to induce some
gassing, which mixes the electrolyte, bringing the cells to equal potential. In a low
maintenance battery, most of the hydrogen and oxygen gasses will recombine and will
not dry out the battery.
Note that this mode is not run for Gel/AGM batteries.
2.4.2 Ready indicator (Green)
Continuously ON: Indicates that the battery charging process is complete, and full
charge (100%) has been achieved. The charger is now in the maintenance mode (Float),
where it will keep the battery at full charge indefinitely without the fear of overcharging.
The battery is ready for use, and can be disconnected.
Flashing: Indicates that the battery charging process is complete, and full charge (100%)
has been achieved. The charger is now in the maintenance mode (Float), where it will
keep the battery at full charge indefinitely without the fear of overcharging. The battery
is ready for use, and can be disconnected.
6
2
OPERATION
2.4.3 Fault indicator (Red)
When faults are detected, the charger shuts down the charging process and displays the
nature of the fault via a Red flashing LED. Possible faults are;
Continuously on - Hardware failure detected:
The SBC1205 failed its self-test on power up. The unit should be returned to the supplier
for inspection.
One Flash - Over current detected:
An excessive current will cause this fault. This will indicate a faulty battery if it occurs
during a charging cycle, but not necessarily if it happens upon connection. This fault may
also be triggered by trying to charge a lower voltage battery than specified e.g. 6V on a
12V charger.
Two Flashes - Voltage problem detected:
A battery that remains at a low voltage for too long or a battery which has a higher
voltage than specified, will cause this fault e.g. attempting to charge a 24V battery on a
12V charger.
Three Flashes - Faulty battery detected:
Charging a battery with a dead cell will result in this fault. With some batteries it might
take longer to detect the fault than in others, depending upon the initial level of charge
and also how damaged the battery is. If the battery is badly damaged, the fault may
show up as over current.
Four Flashes - Overheat:
The charger is too hot to operate, the charging process is suspended, and will
recommence once the charger has cooled down. This can happen on a very hot day,
if the charger is positioned in a very hot place while charging or if the ventilation holes
have been blocked. Also, the fan may not be functioning properly.
If the battery charger detects a fault it will shut down immediately. In this case, check
if connections to the battery are tight. Is the battery sound? Check the electrolyte levels
and use a Hydrometer to check for “dead” cells. A lead-acid battery is considered to be
discharged when the specific gravity of the electrolyte is less than 1.16.
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3
PRECAUTIONS FOR OPERATION
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Ensure the correct battery type has been selected before charging begins.
Before connecting or disconnecting the SBC to a battery, ensure that it is disconnected
from the 240VAC supply.
NOTE disconnecting the battery from the vehicle will cause some components in the
vehicle to lose stored memory or information, such as time on your stereo.
Ensure electrolyte levels in the battery to be charged are sufficient to cover the plates
(if accessible).
DO NOT use the charger to charge a battery near a naked flame. The gasses emitted by
the battery whilst charging may ignite, causing a life threatening fire or explosion.
Always wear eye protection if working close to a charging battery.
Take care whilst handling a lead acid battery, as the electrolyte is acidic and may cause
permanent damage to skin or clothing.
The charger is designed to be used indoors and to be protected from the elements. Do
not expose the battery charger to the weather, particularly rain or dampness.
Provide adequate ventilation whilst charging lead-acid batteries. This will ensure the
charger will work at maximum efficiency and that any gasses emitted from the battery
are safely dissipated.
Do not extend the output cables supplied between the charger and the battery to be
charged, otherwise efficiency of operation will be compromised. Ensure the output
clamps are firmly attached to the battery poles.
Incorrectly connecting the Positive (+ Red wire) and Negative (- Black wire) at the battery will switch off the battery charger to protect it’s internal electronics. Output and
consequent charging will only recommence when the (+) and (-) are correctly attached
to the corresponding (+) and (-) poles on the battery.
Do not obstruct the fan. Note that the fan will run continuously during the charging
cycle.
If the power cord is damaged, it must be replaced by the manufacturer or its service
agent or a similarly qualified person in order to avoid hazard.
The charger is designed to charge batteries constructed with 6 cells only.
For in-vehicle charging,
1. The battery charger must be connected first to the battery terminal which is not
connected to the vehicle chassis. The other connection is to be made to the
chassis, remote from the battery and fuel line. The battery charger is then to be
connected to the supply mains.
2. After charging, disconnect the battery charger from supply mains. Then remove
the chassis connection and the battery connection, in this order.
8
4
OTHER INFO
4.1
Charging Time & Battery Capacity
The charging time is dependant on a number of conditions including the ambient
temperature and the general condition or age of the battery. However it is primarily
dependant on how many Amp-Hours need to be put back into the battery to restore full
charge, rather than the battery capacity itself. For example, a 50% discharged 45Ah
battery requires 22.5Ah to be restored, while a 50% discharged 70Ah battery requires
35Ah to be restored. (Note: Due to inefficiencies in the battery, approximately 10%
more is required to be delivered by the charger in practice). Based on the wide variety
of conditions, the charger can be expected to restore approximately between 1 and 3
Amp-Hours per hour of charge.
To determine if a charger is too big for your battery, use the rule of thumb that the
maximum battery charge current should be typically between 10% and 20% of the
battery Amp-Hour rating. i.e. for a 50Ah battery, the typical maximum charging current
should be less than 20% of 50Ah = 10A.
As a safety precaution, the maximum charge time has been limited to 25 hours. Please
refer to “Ready indicator (Green) Flashing” in section 3.1 for a description of what happens if the charge cycle does time out.
4.2
Calcium Batteries
In the Calcium battery selection mode the charger can achieve a maximum
voltage of 16.5V (33V for 24V unit), the following precautions should be taken:
•
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•
Vehicle ignition must be OFF
Vehicle lights must be OFF
Accessories must be OFF. This includes mobile telephones, radios and sound
systems, DVD players and any other non ignition activated accessories installed.
Be sure any caravans or boats connected to the vehicle, where the battery
is being charged also have all their electrical systems turned off. A good
precaution is to disconnect the trailer / caravan plug from the towed vehicle.
Most new vehicles can tolerate this voltage without damage to the vehicle
electrical system. To ensure that your electrical system will tolerate this
maximum charging voltage, please contact your vehicle service centre.
9
5
TWO YEAR PRODUCT WARRANTY
Over the last three decades our company has established a reputation as the power conversion specialist.
A 100% Australian-owned company, we have met the needs of customers in transport and other industries through exciting, innovative thinking.
We believe in total customer satisfaction and practice this by offering our customers:
•
Technical advice free of jargon and free of charge
•
Prompt turnaround of orders throughout Australia and globally
•
Friendly, personalised, professional service and product support
In the unlikely event that a technical issue arises with a Redarc product, customers are encouraged to initially contact the Redarc Technical Support Team on (08) 8322 4848
or power@redarc.com.au for prompt and efficient diagnosis and product support.
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.
The benefits of this Warranty are in addition to other rights and remedies available at law in respect of the Products and shall not derogate from any applicable mandatory statutory
provisions or rights under the Australian Consumer Law.
Redarc Electronics Pty Ltd atf the Redarc Trust trading as Redarc Electronics (“Redarc
(“Redarc”)
”) offers a warranty in respect of its Products where the Products are purchased from an
authorised distributor or reseller of Redarc by a person (“Purchaser
(“Purchaser”),
”), on the terms and conditions, and for the duration, outlined below in this document (“Warranty
(“Warranty”).
”).
1. In this Warranty, the term Products means:
1.1 all products manufactured or supplied by Redarc (excluding its solar products
which are covered by Redarc’s Solar Product Warranty); and
1.2 any component of or accessory for any product in clause 1.1 manufactured or
supplied by Redarc.
Offer and duration of product warranties
2. Redarc warrants that its Products will be free, under normal application, installation,
use and service conditions, from defects in materials and workmanship affecting
normal use, for 2 years from the date of purchase (Warranty Period).
3. Where a Product malfunctions or becomes inoperative during the Warranty Period,
due to a defect in materials or workmanship, as determined by Redarc, then subject
to further rights conferred by the Australian Consumer Law on the Purchaser,
Redarc will, in exercise of its sole discretion, either:
3.1 repair the defective Product;
3.2 replace the defective Product; or
3.3 provide a refund to the Purchaser for the purchase price paid for the defective
Product,
without charge to the Purchaser.
4. The warranty given by Redarc in clause 3 covers the reasonable costs of delivery
and installation of any repaired or replaced Products or components of Products
to the Purchaser’s usual residential address notified to Redarc, together with the
reasonable costs of removal and return of any Products determined by Redarc to be
defective.
5. If the Purchaser incurs expenses of the nature referred to in clause 4 in the
context of making a claim pursuant to this Warranty that is accepted by Redarc,
the Purchaser will be entitled to claim for reimbursement of those expenses which
Redarc determines, in exercise of its sole discretion, to be reasonably incurred,
provided that the claim is notified to Redarc in writing at the postal address or email
address specified in clause 21 and includes:
5.1 details of the relevant expenses incurred by the Purchaser; and
5.2 proof of the relevant expenses having been incurred by the Purchaser.
Exclusions and limitations
6. This Warranty will not apply to, or include any defect, damage, fault, failure
or malfunction of a Product, which Redarc determines, in exercise of its sole
discretion, to be due to:
6.1 normal wear and tear or exposure to weather conditions over time;
6.2 accident, misuse, abuse, negligence, vandalism, alteration or modification;
6.3 non-observance of any of the instructions supplied by Redarc, including
instructions concerning installation, configuring, connecting, commissioning,
use or application of the Product, including without limitation choice of location;
6.4 failure to ensure proper maintenance of the Product strictly in accordance with
Redarc’s instructions or failure to ensure proper maintenance of any associated
equipment or machinery;
6.5 repairs to the Product that are not strictly in accordance with Redarc’s
instructions;
6.6 installation, repairs or maintenance of the Product by, or under the supervision
of, a person who is not a qualified auto electrician or technician, or if nongenuine or non-approved parts have been fitted;
6.7 faulty power supply, power failure, electrical spikes or surges, lightning, flood,
storm, hail, extreme heat, fire or other occurrence outside the control of
Redarc;
6.8 use other than for any reasonable purpose for which the Product was
manufactured;
6.9 any indirect or incidental damage of whatever nature outside the control of
Redarc.
7. Warranty claims in respect of a Product must be made in writing to Redarc at the
postal address or email address specified in clause 21 within the Warranty Period.
Such claims must include the following:
7.1 details of the alleged defect or fault and the circumstances surrounding the
defect or fault;
7.2 evidence of the claim, including photographs of the Product (where the subject
of the claim is capable of being photographed);
7.3 the serial number of the Product, specified on the label affixed to the Product;
and
7.4 proof of purchase documentation for the Product from an authorised distributor
or reseller of Redarc, which clearly shows the date and place of purchase.
The return of any Products without the prior written instructions of Redarc will not
be accepted by Redarc.
8. Without limiting any other clause in this Warranty, Redarc has the right to reject any
Warranty claim made by a Purchaser pursuant to this Warranty where:
8.1 the Purchaser does not notify Redarc in writing of a Warranty claim within the
Warranty Period;
8.2 the Purchaser does not notify Redarc in writing of a Warranty claim within 1
month of becoming aware of the relevant circumstances giving rise to the
claim, so that any further problems with the Product are minimised;
8.3 the serial number of the Product has been altered, removed or made illegible
without the written authority of Redarc;
8.4 the Purchaser is unable to provide proof of purchase documentation in
accordance with clause 7.4 or evidence that the Product was properly installed
and removed (if relevant), and that proper maintenance has been performed
on the Product, by, or under the supervision of, a qualified auto electrician or
technician, in accordance with the instructions of Redarc.
9. If the Product is found to be working satisfactorily on return to Redarc or upon
investigation by Redarc, the Purchaser must pay Redarc’s reasonable costs of
testing and investigating the Product in addition to shipping and transportation
charges. Where Redarc is in possession of the Product, the Product will be
returned to the Purchaser on receipt of the amount charged.
10. Any replaced Products or components of Products shall become the property of
Redarc.
11. Redarc may, in exercise of its sole discretion, deliver another type of Product or
component of a Product (different in size, colour, shape, weight, brand and/or
other specifications) in fulfilling its obligations under this Warranty, in the event
that Redarc has discontinued manufacturing or supplying the relevant Product or
component at the time of the Warranty claim, or where such Product or component
is superior to that originally purchased by the Purchaser.
Other conditions of Warranty
12. If the Purchaser acquired a Product for the purpose of resupply, then this Warranty
shall not apply to that Product.
13. In particular, the sale of a Product via an online auction, online store or other
internet website by a party that is not an authorised distributor or reseller of the
Product will be deemed to be a resupply within the meaning of the Australian
Consumer Law and will render this Warranty void, as Redarc has no control over the
storage, handling, quality or safety of Products sold by such persons.
14. A Purchaser shall only be entitled to the benefit of this Warranty after all amounts
owing in respect of the Product have been paid.
15. While Redarc warrants that the Products will be free from defects in materials and
workmanship in the circumstances set out in this Warranty, to the maximum extent
permitted by law Redarc does not warrant that the operation of the Products will be
uninterrupted or error-free.
16. To the maximum extent permitted by law, Redarc’s determination of the existence of
any defect and the cause of any defect will be conclusive.
17. Spare parts or materials for the Products are guaranteed to be available for a period
of at least 2 years after purchase of the Products.
18. The agents, officers and employees of any distributor or reseller of the Products and
of Redarc are not authorised to vary or extend the terms of this Warranty.
19. Redarc shall not be responsible or liable to the Customer or any third party in
connection with any non-performance or delay in performance of any terms and
conditions of this Warranty, due to acts of God, war, riots, strikes, warlike conditions,
plague or other epidemic, fire, flood, blizzard, hurricane, changes of public policies,
terrorism and other events which are beyond the control of Redarc. In such
circumstances, Redarc may suspend performance of this Warranty without liability
for the period of the delay reasonably attributable to such causes.
20. If a clause or part of a clause in this Warranty can be read in a way that makes it
illegal, unenforceable or invalid, but can also be read in a way that makes it legal,
enforceable and valid, it must be read in the latter way. If any clause or part of
a clause in this Warranty is illegal, unenforceable or invalid, that clause or part is
to be treated as removed from this Warranty, but the rest of this Warranty is not
affected.
Redarc’s contact details
21. Redarc’s contact details for the sending of Warranty claims under this Warranty are:
Redarc Electronics Pty Ltd
23 Brodie Road (North), Lonsdale SA 5160
Email: power@redarc.com.au
Telephone: +61 8 8322 4848
10
Free technical assistance!
please contact
Redarc Electronics
23 Brodie Road North, Lonsdale SA
(08) 8322 4848
power@redarc.com.au
www.redarc.com.au
Copyright © 2012 Redarc Electronics Pty Ltd. All rights reserved.
WARSBC - REV1
www.redarc.com.au