Battery type Model: OC1206U Models: OC1206U//OC1212U OC1212U OWNER’S MANUAL MANUAL OWNER’S Australian&&New NewZealand ZealandSTANDARD STANDARDAS/NZS AS/NZS60335.2.29 60335.2.29APPROVED APPROVED Australian Congratulations on purchasing an Oz Charge fully automatic switched mode 12 Volt battery charger, maintainer and rejuvenator. Please take the time to carefully read and understand this manual before using this product. IMPORTANT SAFETY ADVICE AND WARNINGS • • • • • • • • • • • • • • The charger is designed to charge and maintain 12V conventional lead-acid batteries only. (VRLA), AGM, CALCIUM, GEL & WET. Always refer to the battery manufacturers specifications and recommendations if you’re unsure of your battery charging requirements. Eg. Such as removing or not removing cell caps whilst charging, battery type, maximum charge rate etc.. Explosive gases may escape from the battery during charging so please ensure the battery is charged in a well ventilated area. This charger is designed for indoor use only and should never be exposed to water, rain, snow, liquids etc. Do not attempt to use the charger if it has been dropped or damaged. Do not attempt to use the charger if the cables or plugs are damaged. If battery acid contacts your skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flush the eye with running cold water for at least 10 minutes and seek medical attention. Someone should always be within range of your voice. Never attempt to charge a damaged battery, frozen battery or non rechargeable battery. Never place the charger on the battery or battery on the charger. When working with lead-acid batteries, remove personal metal items such as rings, bracelets, necklaces, watches and make sure you don’t short circuit the battery terminals with any type of metal tool or piece of jewellery as this will cause an explosion. You can wrap your spanner with insulation tape to minimise the risk of a short circuit. NEVER smoke, use an open flame or create sparks near a battery or charger during charging operation as this may cause an explosion and explosive gases. Do not disassemble the charger. Take it to a qualified and authorised person for repair. If using a generator, you must ensure you use a surge protector to protect the charger from voltage spikes. The charger must not be used or played with by infirm persons or children. Also keep it away from any pets. MAIN FEATURES • • • • • • 100% automatic smart battery charger & maintainer with reconditioning. The battery charger is easy to use and requires no technical experience. Fully microprocessor controlled with safety timers at every stage. Battery condition analysis. Selectable battery type. Selectable charge rate / mode. 1 • Oz Charge manual www.ozcharge.com.au VEHICLE RTHED) Gel • • • • • • • • • Patented battery rejuvenation (reconditioning). Battery voltage retention analysis. Pulse charge for long term maintenance. RED BLACK Ultra lower power consumption (ECO Mode) Multi Stage: 1 - Qualification - Battery condition check CONNECTION IN VEHICLE 2 - Battery rejuvenation (recondition (POSITIVELYmode) EARTHED) 3 - Soft start charging 4 - Bulk charging 5 - Absorption charging 6 - Equalisation charging 7 - Battery analysis 8 - Float mode 9 - Long term maintenance pulse charge Automatic diagnosis and charge: On power up, the charger will automatically diagnose the battery condition and determine if the rejuvenation mode (reconditioning) or charge cycle is required. Patented battery rejuvenation technology: The charger has a unique and patented rejuvenation feature which uses high voltage equalising and peak pulse reconditioning to repair sulphated batteries. This feature is fully automatic and depends on the internal impedance of the battery. It also depends on whether the battery is still connected in the vehicle. Can be left on 24/7 to ensure your battery is always maintained and fully charged: The battery charger can be left unattended and left permanently connected all year round. The intelligent charger will monitor the battery voltage and will maintain it at peak performance with a special pulse charge during long term maintenance. Short circuit and reverse polarity protection: Heavy-duty and corrosion-resistant output connectors: Crocodile clips: It comes with a quick connect fly lead and heavy duty, fully insulated crocoGel dile clip harness. If you require an optional ring terminal harness, please visit our website Battery type www.ozcharge.com.au or contact your local reseller. Gel Battery type Battery type • • • BLACK • • Rapid Charge Mode: Uses maximum charging current to ensure the fastest charge time. You may here the fan turn on during this mode. Silent Charge Mode: Charges at a slightly reduced charge rate so the cooling fan is not required. Maintenance Mode: Ideal and recommended for long term maintenance charging or for charging smaller batteries. 2 • Oz Charge manual Note: Image shows OC1206U model. www.ozcharge.com.au TEMPERATURE & SAFETY PROTECTION: • • • • • INTERNAL OVERHEAT PROTECTION: The charger has a built-in overheat and an overload electronic circuit. This protects the charger from being damage if overheated or overloaded and will automatically decrease the charging current. Once the units internal temperature decreases to a safe level, the charger will resume normal charging. SAFETY TIMER PROTECTION: The charger has safety timers for every stage. If the battery voltage doesn’t reach a certain voltage within a certain time, the unit will stop charging as it’s highly likely that you’re attempting to charge a severely discharged or heavily sulphated battery. If any of the stages time out, the charger will immediately stop charging in order to protect the battery. This will be indicated with the fault LED flashing slowly. REVERSE POLARITY: The charger has reverse polarity protection. If the charger output leads are connected reverse polarity, the fault LED will come on and the charger will be disabled. Simply unplug the charger from AC power and then connect the output leads to the correct polarity. SHORT CIRCUIT PROTECTION: The charger will automatically turn off if the output leads are short circuited and the fault LED will come on. This prevents the charger from being damaged if the positive and negative crocodile clips or the optional ring terminals accidently touch each other while the charger is turned on. ECO MODE: This Oz Charge battery charger has a built in ultra low power consumption circuit. If AC power is connected and the battery is disconnected, after 10 seconds the charger will automatically go into an ECO mode. During this mode the power drawn is less than 0.36W which totals 0.01kWh per day power consumption. If AC power is connected and the battery is connected, once the battery is fully charged and during the long term maintenance stage, the total power consumption is around 0.03kWh per day. Both the selected Charge rate and Battery type LED’s will flash GREEN to indicate ECO mode. BATTERY TYPES & CAPACITY: • Suits 12V conventional lead acid batteries (VRLA) AGM, Calcium, Gel & Wet. The Ah (Ampere Hours) capacities shown below are to be used as a general guide only. Some batteries may be able to handle a higher charge current. Refer to the battery manufacturers specifications and recommendations for your charging requirements. OC1206U Charge Rate: OC1212U 1A 4A 6A 1A 8A 12A Charging 3 - 20Ah 12 - 80Ah 18 - 120Ah 3 - 20Ah 24 - 160Ah 36 - 240Ah Maintaining < 100Ah < 120Ah < 180Ah < 100Ah < 240Ah <360Ah 3 • Oz Charge manual www.ozcharge.com.au ELECTRICAL PARTS & ACCESSORIES: AC Power Cord: 1.8m with SAA 2 Pin AU Plug DC Output Lead: 1.2m with quick connect Charging Leads: Quick connect 60cm Crocodile Clip Harness TECHNICAL SPECIFICATIONS: Model Number OC1206U OC1212U Output 6A @ 12V 12A @ 12V Input Voltage 100-240Vac / 1.4A(95W) 220-240Vac / 1.8A(175W) Input Frequency 50/60Hz 50/60Hz Charge Voltage Gel - 14.1V AGM&WET - 14.4V Calcium - 14.7V Gel - 14.1V AGM&WET - 14.4V Calcium - 14.7V Equalising Voltage Gel - 14.3V AGM&WET - 14.6V Calcium - 15.5V Gel - 14.3V AGM&WET - 14.6V Calcium - 15.5V Float Voltage 13.6V 13.6V Start Voltage 3V 3V Operating Temperature -15 to 50° C -15 to 50° C Storage Temperature -25 to 85°C -25 to 85°C Operating Humidity 90% RH Max. 90% RH Max. Size (L*W*H) 182mm x 88mm x 48mm 214mm x 103mm x 55mm Weight 0.75kg Approvals CE, UL/cUL, AS/NZS, EMC CE, UL/cUL, AS/NZS, EMC 1.1kg CHARGING INSTRUCTIONS: STEP 1 - Pre charge check & electrolyte level check • • • Check the Battery Electrolyte levels (Not required on sealed & maintenance free batteries). If necessary, remove the vent caps and add distilled water so the levels are halfway between the upper and lower fill lines. Check the battery voltage, type and Ah capacity to ensure the charger is compatible and to determine which Battery Type and Charge Rate settings you will use. Ensure the battery is in a well ventilated area and the charger should be as far away from the battery as the cables permit. 4 • Oz Charge manual www.ozcharge.com.au STEP 2 - Connecting the battery charger to your battery • If the Battery is out of the vehicle: - Connect the Red (+) Crocodile clip or optional ring terminal to the (+) battery terminal. - Connect the Black (-) Crocodile clip or optional ring terminal to the (-) battery terminal. Gel Battery type RED BLACK Gel Battery type • If the battery is still in the vehicle, determine if the vehicle is positively or negatively earthed. If Negatively Earthed (Most Common) – FIRST Connect the Red (+) Crocodile clip or optional ring terminal lead to the (+) battery terminal and then connect the Black (-) Crocodile clip or optional ring terminal lead to the vehicle’s chassis. DO NOT connect the Black (-) lead to the carburettor or fuel lines. RED BLACK Gel Gel Battery type Battery type RED RED BLACK BLACK CONNECTION IN VEHICLE (POSITIVELY EARTHED) CONNECTION IN VEHICLE (NEGATIVELY EARTHED) Gel Gel Battery type Battery type RED BLACK BLACK Gel Battery type RED CONNECTION IN VEHICLE (NEGATIVELY EARTHED) BLACK CONNECTION IN VEHICLE (POSITIVELY EARTHED) Battery type Gel Battery type If Positively Earthed – FIRST Connect the Black (-) Crocodile clip or optional ring terminal lead to the (-) battery terminal and then connect the Red (+) Crocodile clip or optional ring terminal lead to the vehicle’s chassis. DO NOT connect the Red (+) lead to the carburettor or fuel lines. Gel Gel RED BLACK BLACK Gel Battery type Battery type RED CONNECTION IN VEHICLE (POSITIVELY EARTHED) CONNECTION IN VEHICLE (NEGATIVELY EARTHED) Gel Gel Battery type STEP 3 - Connect the battery charger to Mains Power (240Vac) Battery type • The charger will automatically start when AC power is connected and switched on. • IMPORTANT: Please make sure the correct Battery Type and your desired Charge Rate is selected to suit your battery by pressing the Select Buttons within the first 5 minutes of chargGel ing. For Example do not charge a Gel Battery on the Calcium Battery Type setting as this may Battery type damage your battery and / or reduce your battery life. Note: If the Fault Indicator LED illuminates Red, please check your connections as it’s likely that the Positive and Negative Leads are reversed. 5 • Oz Charge manual www.ozcharge.com.au RED THE CHARGING PROCESS: 1) Qualification - Battery Condition Check When the charger is first switched on it checks the battery condition to determine whether the battery needs reconditioning. During this qualification process it checks the internal impedance and initial voltage of the battery and it will determine how much charge current, if any that the battery will accept. 2) Enhanced Battery Rejuvenation - Blue Bulk LED Flashing Fast If the initial qualification detected that the battery was in poor condition, the patented rejuvenation process will begin automatically. During the rejuvenation process a high voltage equalising and peak pulse reconditioning charge is used to repair the sulphated battery. This unique patented feature will break down and dissolve the lead-sulphate crystal build up on the battery plates which will extend the life of your battery. It can also balance out high concentrations of acid. The equalisation voltage will be 16V maximum. If the battery voltage doesn’t reach 9V within 24 hours, the Rejuvenation process will time out. 3) Soft Start Charging - Blue Bulk LED Flashing Slow Gently charges the battery using a reduced charge output until the battery voltages reaches 11V. If the battery voltage doesn’t reach 11V within 6 hours, the safety timer protection will stop the unit from charging and the Red Fault LED and Blue Bulk LED will start flashing. 4) Bulk Charging - Blue Bulk LED ON (Charge Voltage depends on battery type selection) Uses the maximum selected charge output until the battery voltage reaches 14.1/14.4/14.7V. If the battery voltage doesn’t reach this within 24 hours, the safety timer protection will stop the unit from charging and the Red Fault LED will start flashing and the Blue Bulk LED will be ON. 5) Absorption Charging - Green Absorption LED ON Uses a constant voltage while reducing the charging output current to ensure the battery receives a full charge without overcharging the battery. 6) Equalisation Charging - Blue Bulk LED and Green Absorption LED both flashing A well proven process that carefully overcharges the battery to restore it’s full capacity. The Equalisation stage for CALCIUM Battery type selection is automatic. The Equalisation stage for AGM&WET and GEL Battery Types only occurs if the initial start voltage is below 11 Volts. 7) Battery Analysis - Green Full LED ON The battery analysis stage checks the condition of the battery after the charge cycle is completed. If the battery voltage drops too quickly during the analysis mode, this means the battery is probably faulty. If the battery analysis failed, this is indicated by the Green Full LED flashing. 8) Float Mode - Full Green LED ON This stage allows you to keep the charger connected 24/7 to ensure your battery is well maintained and kept 100% fully charged. Float mode will maintain the battery at a constant 13.6V. 6 • Oz Charge manual www.ozcharge.com.au RED BLACK CONNECTION IN VEHICLE (POSITIVELY EARTHED) CONNECTION IN VEHICLE (NEGATIVELY EARTHED) 9) Long Term Maintenance - Full Green LED ON During long term maintenance / float mode, the unit will apply a special pulse charge to ensure the battery is kept in optimal condition. STEP 4 - Disconnecting the Battery charger from Battery If the Battery is out of the vehicle: (1) Switch OFF and Remove the AC Power Socket from the outlet. (2) Remove the Black lead and then the Red lead. • If the battery is still in the vehicle: (1) Switch OFF and Remove the AC Power Socket from the outlet. (2) Remove the lead from the vehicle chassis. (3) Remove the lead from the battery. Note: Check electrolyte levels if possible after charging as they may need topping up with distilled water. (This does not apply to sealed maintenance free batteries) Gel Battery type • LED STATUS INDICATOR TABLE: Gel Battery type Note: Image shows OC1206U model. LED Status Description Battery Type LED’s Green ON Indicates which Battery Type is selected ON Indicates which Charge Rate / Charge Mode is selected Charge Rate LED’s Green Charging Status LED’s Full Green Flash/ON Flashing if Analysis failed or ON if fully charged - Float / Maintenance mode Absor. Green Flash/ON Flashing during equalisation charging or ON during Absorption charging Bulk Blue Flash/ON Fast Flash - Rejuvenation / Slow Flash - Soft Start charging / ON - Bulk charging Fault LED Red ON Red Flashing Short circuit/reverse polarity or Rejuvenation failed if Bulk LED also flashing slow Over temperature protection mode / Soft start charging timed out if Blue Bulk LED also flashing fast / Bulk charging timed out if Blue Bulk LED also ON 7 • Oz Charge manual www.ozcharge.com.au CHARGING CURVE 8 • Oz Charge manual www.ozcharge.com.au TROUBLE SHOOTING Problem Indication Possible Causes Suggested Solution Charger does not work? No Indicator lights on - No AC power - Check AC connections and make sure the AC Power Point is switched ON. - Try a different AC Power Point which you know is working. Charger has no DC output? Fault Red LED is ON - Output is short circuited - Reverse polarity protection - Loose / bad connection to the battery - Check DC connection between charger and battery and make sure they are not short circuited. (Touching each other) - Check that the crocodile clips have not fallen off or come loose. - Check that the crocodile clips/ ring terminals are connected to the correct polarity. Note: The charger output is only present when connected to a battery. No charging current? Fault Red LED is Flashing - Battery is severely sulphated - Battery has a damaged cell - Overheat protection mode - Check the battery condition, age etc. - Battery may need replacement. - Move battery & charger to a cooler environment. The full / float light won’t come on. - Battery Ah capacity too large for the battery charger and it has time out - Battery is defective - Battery is severely sulphated - Check the charger specifications match the battery capacity. Eg. make sure battery capacity is not too big for the charger. - Battery may need replacement. - Charge rate selected might be too low for the battery. Switch charger off and on and try again or try a higher charge rate setting providing it doesn’t exceed the maximum charge limit for your battery. Fault Red LED is Flashing or Full Green LED is Flashing REPLACEMENT PARTS For the full range of replacement parts and accessories, please visit our website: www.ozcharge.com.au. / www.ozcharge.co.nz 9 • Oz Charge manual www.ozcharge.com.au 2 YEAR PRODUCT WARRANTY Zylux Distribution Pty. Ltd. (ABN 66 101 378 009) of 166 Christmas Street, Fairfield, Victoria, 3078, Australia warrants to the Customer that this product is substantially free from defects in materials and workmanship under normal use for a period of Two Years from the Date of Purchase. Please ensure you keep a copy of your purchase receipt on file as this will be required to validate your warranty. Obtaining Warranty Service: Within the warranty period, the Customer must contact the authorised supplier / retailer where the product was purchased or alternatively you can contact the Oz Charge service centre through one of the following methods: Service help phone: Within Australia (03) 9482 2203 Outside of Australia: +61 3 9482 2203 Website: www.ozcharge.com.au / www.ozcharge.co.nz If the Authorised Supplier and / or Oz Charge service centre concludes that while under normal use, a product failure or malfunction occurred during the warranty period and was caused by a defect in material or workmanship (see Exclusions), the Customer will be asked to ship to the nearest service point for repair or replacement, at our discretion. The product must be packaged appropriately for safe shipment. To prove that the product is under warranty, the customer should enclose a copy of their receipt for proof of purchase. It is recommended that returned products be sent by registered mail as Zylux Distribution Pty. Ltd. (Oz Charge) accepts no responsibility / liability for goods lost or damaged in transit. Exclusions: If upon receiving a product for repair and if testing and examining the product has disclosed that the alleged defect or malfunction in the product does not exist or was caused by the Customer or any third persons misuse, neglect, physical abuse, water damage, unauthorised attempts to open, exposure to extremely high temperatures, tampered with or repaired by an unauthorised persons, this will not be covered under this warranty. Also charges may apply to any product returned which has no fault found or if the warranty has expired or been void. This Warranty is also void if: 1. The warranty seal is broken or altered. 2. The warranty period has expired. 3. The product has been tampered with or repaired by an unauthorised person. 4. If used on a generator without using a surge protector. 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. For New Zealand customers, this warranty is in addition to statutory rights observed under New Zealand legislation. 10 • Oz Charge manual www.ozcharge.com.au SAA Approval No. GMA-102826-EA-002 / GMA-102826-EA-003 OC1206U / OC1212U Owner’s Manual: Rev 1.1 - 11/14 - Specifications subject to change without notice.