PRO-CHARGE
BATTERY CHARGER
6 STAGE SWITCHMODE
P/No.s PC400, PC800, PC1600, PC2100
IMPORTANT SAFETY INFORMATION
Please read this manual thoroughly before use and store in a safe place for future reference.
WARNING
•Explosive gases may escape from the battery during charging. Prevent flames and
sparks. Provide adequate ventilation.
•Before charging, read the instructions.
•For indoor use. Do not expose to rain.
•For charging 12 Volt lead acid batteries ONLY.
•Disconnect the 240V mains supply before making or breaking the connections to the
battery.
•The battery charger must be plugged into an earthed socket-outlet.
•Connection to supply mains is to be in accordance with National wiring rules.
•Do not attempt to charge non-rechargeable batteries.
•Never charge a frozen battery.
•If the AC cord is damaged do not attempt to use. It must be replaced or repaired by a
qualified person.
•Corrosive substances may escape from the battery during charging and damage delicate
surfaces. Store and charge in a suitable area.
•Ensure all vehicle accessories including lights, heaters, appliances etc are turned off
prior to charging.
•This appliance is not intended for use by young children or infirm persons unless they
have been adequately supervised by a responsible person to ensure that they can use
the appliance safely.
•Young children should be supervised to ensure that they do not play with the appliance.
2
6-STAGE AUTOMATIC CHARGING
This is a fully automatic battery charger with 6 charge stages.
Automatic charging protects your battery from being overcharged so you can leave the
charger connected to the battery indefinitely.
6-stage charging is a sophisticated charging technique that gives your battery longer life
and better performance compared to using traditional chargers.
Projecta’s Pro-Charge chargers are suitable for most 12V automotive, marine and deep
cycle batteries. They may also help restore drained and sulphated batteries.
The 6 charge stages are:
Rejuvenation; Soft Start; Bulk; Absorption; Battery Test and Float.
REJUVENATION
The rejuvenation stage is manually initiated and delivers a 24 hour high frequency,
intermittent charge that breaks down sulphation from the battery’s plates. Upon
completion, the charger will proceed to Soft Start.
SOFT START
This is a preliminary charge process that gently introduces power to the battery,
protecting the battery and increasing battery life.
BULK (CONSTANT CURRENT)
The Bulk stage reduces charging time by charging the battery at the maximum rate
(constant current) to a set voltage, at which point the battery is approximately 80%
charged.
ABSORPTION (CONSTANT VOLTAGE)
The absorption stage charges the battery to 100% by adjusting the charge rate allowing
the battery to absorb more power.
EQUALISATION (CALCIUM MODE ONLY)
Designed especially for calcium batteries, this stage returns calcium batteries to full
service by removing acid stratification of the electrolyte.
BATTERY TEST
The analysis mode tests the battery to ensure that it has taken the charge; if the
battery passes the test the charger will proceed to the float stage.
FLOAT
The Float stage maintains the battery at 100% charge without overcharging or
damaging the battery. This means the charger can be left connected to the battery
indefinitely.
3
FEATURES
CALCIUM MODE
Pro-Charge’s Calcium mode adjusts the charging profile to suit calcium batteries for
complete and proper charging. This charge mode is best suited to Calcium batteries
that have been deeply discharged and require an equalisation charge to restore a full
electrolyte reading.
REJUVENATION MODE
Pro-Charge’s Rejuvenation mode can restore tired batteries by breaking down
sulphation and revitalising the battery cells, increasing battery life and performance.
ADJUSTABLE CHARGE RATE
The charger’s output can be adjusted to suit the size of the battery for optimum
charging.
SWITCHMODE TECHNOLOGY
Using the latest technology in battery chargers, switchmode chargers convert 240V AC
power to 12V DC power using electronic components unlike traditional battery chargers
that rely on heavy transformers. This allows the charger to be lightweight and compact
without sacrificing on performance.
SPARK-FREE AND POLARITY PROTECTED
All Pro-Charge battery chargers are spark-free and are protected against accidental
reverse connection making them safer to use around batteries.
4
MOUNTING INSTRUCTIONS
Pro-Charge chargers are designed for indoor, out of weather use only. Ensure that both
charger and battery are in a well-ventilated space during charging.
The battery charger includes optional side wings for easy mounting. If permanently
fixed, attach side wings to the base of the charger using the supplied screws as
illustrated1. The charger should then be mounted to a suitable horizontal or vertical
panel2 with at least 10cm clearance around the charger to provide adequate ventilation
for the cooling vents.
2
1
CONTROLS
The battery charger’s interface allows you to control the charge rates and charge modes
to best suit your battery. The functions of the buttons are explained below:
1. BATTERY TYPE: Set the charge mode (Normal, Calcium, Rejuvenation)
2. CHARGE RATE: Set the charge rate to suit the size of the battery
5
LED CHARGE INDICATORS
These battery chargers include coloured LEDs that illuminate various signals to indicate
different stages of charging.
LED Signals: PC400 & PC800
LED
LED SIGNAL & STAGES OF CHARGING
Rejuvenation
Soft Start
Flashing Bulk
(Blue)
– – –
Bulk Charge Absorption
Solid On Solid On
Analysis
Float
Solid On
–––––– ––––––––––––
Full
(Green)
Flashing – – –
RejuvenationFlashing
(Amber)
– – –
Fault (Red)
Equalisation
Flashing
Solid On
– – –
––––––
Analysis
Float
Flashing
Solid On
Flashing
–––
Fault (See Faults & Errors, page 12)
LED Signals: PC1600 & PC2100
LED
LED SIGNAL & STAGES OF CHARGING
Rejuvenation
Soft Start
Flashing Bulk
(Blue)
– – –
Bulk Charge Absorption
Equalisation
Solid On ––––––
Absorbtion
Solid On
Solid On
(Blue)
––––––––––––
Full
(Green)
RejuvenationFlashing
(Amber)
– – –
Fault (Red)
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Fault (See Faults & Errors, page 12)
– – –––––––
Flashing
– – –
CHARGING INSTRUCTIONS
STEP 1 – CHECK THE ELECTROLYTE LEVEL
Prior to charging the battery, remove the vent caps and check the electrolyte level (not
required on sealed & maintenance free batteries). The electrolyte should be 6mm (1/4”)
above the battery’s plates. If low, top up with distilled water to the correct level and
refit the vent caps.
STEP 2 – CONNECT TO BATTERY
There are three options for connecting to a battery.
Step 2A – Connecting to a battery that is out of the vehicle
Step 2B – Connecting to a battery fitted to a vehicle
Step 2C – Permanent hard wiring connection to a battery
STEP 2A – BATTERY OUT OF VEHICLE
Connect the RED lead (battery clip) from the charger to the Positive (+) battery post.
Connect the BLACK lead (battery clip) from the charger to the Negative (-) battery post.
Connection out of vehicle
7
STEP 2B – BATTERY IN VEHICLE
Determine if the vehicle is Positively (+) or Negatively (-) earthed. Negatively earthed
vehicles have a cable (usually black) from the Negative battery terminal to the vehicle’s
chassis.
Negatively earthed (most vehicles)
Connect the RED lead (battery clip) from the charger to the Positive (+) battery terminal.
Connect the BLACK lead (battery clip) from the charger to the vehicle’s chassis away
from the fuel line or moving parts.
Connection in vehicle
(negatively earthed)
Positively earthed
Connect the BLACK lead (battery clip) from the charger to the Negative (-) battery
terminal.
Connect the RED lead (battery clip) from the charger to the vehicle’s chassis away from
the fuel line or moving parts.
Connection in vehicle
(positively earthed)
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STEP 2C – PERMANENT HARD WIRING
It is possible to hard wire the DC charging leads to the battery for permanent
installations.
You will need 2 x ring terminals, an inline fuse holder and a fuse with the following
ratings. (See below)
PC400 = 7.5 Amp fuse
PC800 = 10 Amp fuse
PC1600 = 30 Amp fuse
PC2100 = 30 Amp fuse
Connection:
1. Cut off the supplied battery clips; ensure you leave sufficient cable to reach the
battery terminals. (DO NOT extend the battery charger DC leads, as the added
voltage drop will cause incorrect charging).
2. Fit a ring terminal to the BLACK Negative (-) wire.
3. Connect an inline fuse to the RED Positive (+) wire.
4. Connect a ring terminal to the other end of the inline fuse.
5. Connect the RED lead (with inline fuse and ring terminal) to the Positive (+)
battery post.
6. Connect the BLACK lead (with ring terminal) to the Negative (-) battery post.
Inline fuse
Ring terminal
7. Fit the correctly rated fuse.
If the charger is used in a Permanent/Hard Wired application and the vehicle will not
be used for some time, it is best to leave the charger connected to mains power (turned
‘On’) so that it can maintain the battery fully charged.
Ensure any modification to the 240V mains lead is carried out by a qualified person and
that connection to supply mains is in accordance with National wiring rules.
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STEP 3 – CONNECT TO 240V MAINS POWER
Connect the battery charger to the 240V mains powered socket and turn on the mains
power.
STEP 4 – SET CHARGE RATE
The charge rate should be set according to the size of the battery. To set, press the
CHARGE RATE button repeatedly until desired setting is displayed.
See the recommended charge rates for various battery sizes in the table below.
(Not all outputs are available on all models)
ADJUSTABLE CHARGE RATES:
CHARGE RATE
1 Amp 2 Amp 4 Amp 6 Amp 8 Amp 12 Amp 16 Amp 21 Amp BATTERY SIZE (12V)
Deep Cycle (AH)
7-20 14-40 30-80 40-120 60-160 80-240 110-320 150-420 Automotive (CCA)
40-120 80-240 180-480 240-720 360-1000 480-1440 660-1900 900-2500 Marine (MCA)
55-170 110-330 250-650 330-1000 500-1300 660-2000 930-2700 1200-3500 Time (Hrs)
7-24
7-24
7-24
7-24
7-24
7-24
7-24
7-24
STEP 5 – SET BATTERY TYPE
The battery type should be set according to the type of battery being charged:
Normal (NORM) setting: suits GEL, AGM, WET batteries
Calcium (CAL) setting: suits CALCIUM batteries
To set, press the BATTERY TYPE button repeatedly until desired setting is displayed.
STEP 6 – CHARGING
During normal charging the LED panel will illuminate various signals, indicating the
different stages of charging.
When the battery is fully charged, the green FLOAT LED will illuminate. This indicates
the charger is in the float stage and the charger can be left connected to the battery
without over charging.
If the red FAULT LED illuminates, there is a fault; refer to the “Fault & Errors”
explanation on page 12 of this manual.
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STEP 7 – DISCONNECTION
Ensure the 240V mains switch is turned off and the charger is disconnected from the
240V mains power.
Battery out of vehicle
Remove the BLACK lead (battery clip) from the battery.
Remove the RED lead (battery clip) from battery.
Battery in vehicle
Remove the chassis connection.
Remove the battery terminal connection.
STEP 8 – CHECK THE ELECTROLYTE LEVEL (CALCIUM MODE ONLY)
Check the electrolyte level and top up if required.
INITIATING REJUVENATION MODE
The rejuvenation mode can restore batteries from a deeply discharged state by breaking
down sulphation and revitalising the battery cells. A rejuvenation charge should be
performed periodically to optimise the battery‘s health and performance.
STEP 1
Follow STEPS 1 to 6 of the “Charging Instructions” of this booklet.
STEP 2 – HOLD DOWN THE BATTERY TYPE BUTTON
Hold the BATTERY TYPE button down for approx. 3 seconds until the REJUVENTATION
(REJ) LED begins flashing.
The charger will be in this mode for 24 hours, but can be manually stopped by holding
the BATTERY TYPE button down for approx. 3 seconds until the REJUVENTATION (REJ)
LED turns off.
Upon completion of the recondition, the charger will proceed to carry out a normal
charge on the battery.
STEP 3
Follow STEPS 7 to 9 of the Charging Instructions of this booklet.
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FAULTS & ERRORS
There are 6 possible error signals that may be displayed. These are explained in the
following table:
Fault (Red LCD)
Bulk
(Blue LED)
Full
(Green LED)
Solid On
Flashing
–––––
–––
Rejuv
(Amber LED)
Flashing
–––
Solid On
Flashing
––––– – – –
Solid On
Solid On
–––––––––––
Solid On
–––––
Solid On
Flashing
–––––
–––
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Fault Remedy
Battery
problem has
been detected
Initiate Rejuvenation
mode. If it fails again
the battery may be
faulty
Short circuit
or reverse
connection
of the clips
Check the clips are not
touching each other
OR
Check the clips are
correctly connected
to the battery
Battery
problem has
been detected
Battery may
be faulty and may
need to be replaced
Bulk charging
has timed out
and stopped
after 24 hours
Battery may
be faulty
Over
temperature
Move charger to
a cooler location
OR
Check fan is
working properly
Soft Start has
timed out
Check battery or
remove any load
on the battery
SPECIFICATIONS
P/No.
PC400 PC800
Type 6 stage 6 stage PC1600PC2100
6 stage 6 stage
Input (nominal) 240VAC, 50Hz 240VAC, 50Hz 240VAC, 50Hz 240VAC, 50Hz
Input Power 132W 240W 432W 600W
Output Voltage 12V 12V 12V 12V
Output Current 1, 2, 4A 2, 4, 8A 2, 4, 8, 16A 2, 6, 12, 21A
Minimum Start Voltage 3.0V 3.0V 3.0V 3.0V
Back Drain 1mA 1mA 1mA 1mA
CHARGE CONTROL
Rejuvenation
High frequency charge for 24 hours
High frequency charge for 24 hours
High frequency charge for 24 hours
High frequency
charge for 24 hours
Soft Start Half the rated set
current up to 10.5V
Half the rated set
current up to 10.5V
Half the rated set
current up to 10.5V
Half the rated set
current up to 10.5V
Bulk
Set current up to:
14.4V (NORMAL)
14.7V (CALCIUM)
Set current up to:
14.4V (NORMAL)
14.7V (CALCIUM)
Set current up to:
14.4V (NORMAL)
14.7V (CALCIUM)
Set current up to:
14.4V (NORMAL)
14.7V (CALCIUM)
Absorption
Constant voltage 14.4V (NORMAL), 14.7V (CALCIUM) until current drops to the following set points:
1 Amp setting: 0.15A 2 Amp setting: 0.3A
2 Amp setting: 0.3A 2 Amp setting: 0.3A
2 Amp setting: 0.3A 4 Amp setting: 0.6A
4 Amp setting: 0.6A 6 Amp setting: 0.9A
4 Amp setting: 0.6A 8 Amp setting: 1.2A
8 Amp setting: 1.2A 12 Amp setting: 1.8A
16 Amp setting: 2.5A 21 Amp setting: 3.15A
Equalization
(Calcium mode only)
Constant current
Constant current
2.0A up to 16V 2.0A up to 16V then hold for 30 min then hold for 30min or 12 hour timeout
or 12 hour timeout
Analysis
Float
Constant current
Constant current
2.0A up to 16V 2.0A up to 16V
then hold for 30 min then hold for 30 min
or 12 hour timeout
or 12 hour timeout
Stops charging for 5 minutes, tests if battery is above 12.5V
13.7V13.7V 13.7V13.7V
BATTERY RANGE
Deep Cycle
7–80Ah
14–160Ah
14–320Ah
14–420Ah
Automotive
40-480CCA 80-1000CCA 80-1900CCA 80-2500CCA
Marine
55-650MCA 110-1300MCA 110-2700MCA 110-3500MCA
Types of Batteries
Most types of batteries including GEL, AGM, WET CELL and CALCIUM
Size (mm)
167 x 104 x 66 216 x 118 x 66 229 x 137 x 86
229 x 137 x 86
Weight
0.85 kg 1.0 kg 1.5 kg 1.5 kg
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PRODUCT OVERVIEW
Rejuvenation
Mode
Normal & Calcium
Charge Modes
Adjustable
Output
High
Performance
Cooling Vents
Polarity
Protected
Side Mounting
Wings
Moulded
Spark-Free Clips
PC400
PC800
PC1600/PC2100
167
216
229
104
66
118
137
66
86
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FREQUENTLY ASKED QUESTIONS
Q. How do I know if the battery is charged?
A.The charger’s FULL LED will illuminate (solid). Alternatively use a Battery Hydrometer
(Projecta Part No. BH100). A reading of 1.250 or more in each cell indicates a fully
charged battery.
Q.I have connected the charger properly but the BULK LED does not come on.
A. In some cases batteries can be flattened to the point where they have very little or no
voltage. This can occur if a small amount of power is used for a long time, for example
a map reading light is left on for a week or more. Projecta 6 Stage chargers are designed
to charge from as little as little as 3.0 Volts.
If the voltage is lower than the voltages stated above use a pair of booster cables
to connect between two batteries to provide more than 3.0 Volts to the battery being
charged. The charger can then start to charge the battery and the booster cables can
be removed.
Q.Can I use the charger as a power supply?
A.Projecta 6 Stage chargers are designed to only supply power to the battery clips when
they are connected correctly to a battery. This is to prevent sparks during connection to
the battery or if connected incorrectly by mistake. This safety feature prevents the charger
from being used as a ‘Power Supply’
Q.How can I tell what stage the battery charger is in?
A.Coloured LEDs indicate the various stages of charging. Refer to “LED Charge Indicators”
section of this booklet on page 6.
Q. Why does CALCIUM mode take so long to charge?
A.To fully charge a Calcium battery, the battery requires an extra charging stage called
‘Equalisation’. This consists of a constant current being fed into the battery until 16 Volts
is reached. This rejuvenates the battery cells. This charging stage can take up to 12 hours.
Q.Why do I need a special Calcium mode?
A.Because of the different chemistry used to make a Calcium battery, a different charging
algorithm (or technique) is required. Calcium batteries are also affected when deeply
discharged or used heavily. They need to be recharged by a Calcium charger to fully
recharge the battery and to maximize the battery’s life and performance.
Q. What is a Calcium battery?
A.Calcium batteries are lead acid batteries that have had calcium added to the lead plates,
either to one plate (called Calcium Hybrid) or to both plates (called Calcium–Calcium).
The added calcium provides a number of benefits:
i. Lower internal resistance which provides a small increase in CCA performance.
ii. The ability to withstand higher engine bay temperatures.
iii.Low self discharge rate, which increases the shelf life, typically 4 times longer
than a Lead–Lead battery.
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Distributed by
AUSTRALIA
Brown & Watson International Pty Ltd
Knoxfield, Victoria 3180
Telephone (03) 9730 6000
Facsimile (03) 9730 6050
National Toll Free 1800 113 443
NEW ZEALAND
Narva New Zealand Ltd
22–24 Olive Road
PO Box 12556 Penrose
Auckland, New Zealand
Telephone (09) 525 4575
Facsimile (09) 579 1192
IS175
Issue 1 20.01.12