Automatic Battery Charger
Microprocessor controlled with safety timers at every stage
Input: 220-260Vac / Output: 24Volt DC (4 Amps)
User’s Manual and Important Safety Information
Model: PX-2404M (24 Volt – 4 Amp) – Suits Motorised / Mobility Scooters
- - - - - - - - - - - - - - - - - - - WARNINGS - - - - - - - - - - - - - - - - - - - - •
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Read instructions prior to use. These instructions form part of the warranty conditions.
This appliance must not be used or played with by infirm persons or children.
If using Generator power, please use a Surge Protector to protect the unit from Voltage
Spikes.
Do not attempt to use the charger if it has been dropped or damaged.
Never attempt to charge a damaged battery, frozen battery or non-rechargeable battery.
Do not use the charger in a closed area or poorly-ventilated area.
Never smoke, use an open flame, or create sparks near a battery or charger during charging
operation as this may cause an explosion / explosive gas.
Do not operate the charger if the cord or plug is damaged.
Do not disassemble the charger. Take it to a qualified person if a repair is required. (No
serviceable Parts inside)
FEATURES
Congratulations on purchasing an AS/NZS Approved PowEx Automatic Switching Mode Battery
Charger and Maintainer.
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High frequency, High Efficiency Switching Mode
Microprocessor controlled
Suits all Lead Acid Type Batteries. (Conventional, AGM & Gel)
Heavy-duty cables with Amphenol (Cannon) ‘XLR’ type connector
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PX-2404M User’s Manual - Rev 1.6
CONTROL AND INDICATORS
1. Charging Status Display LED (3 x LED’s)
Fault – RED (Refer to LED STATUS INIDACTOR TABLE on Page #4)
Charging Process - Orange
Fully Charged - Green
2. ON / OFF Switch
Main Power Switch for the Charger
RECOMMENDED BATTERY CAPACITY
The maximum recommended battery Capacity for PX2404M (4 Amp) Battery charger is 44AH.
We always recommend that you check the Battery Manufacturers specifications before using
this charger.
OPERATING INSTRUCTIONS
The PowEx Battery Charger is easy to operate and requires no technical experience.
1. Connecting the Battery charger to your Battery
(a) Simply plug the charger lead into the fly lead from your battery (Wheelchair/scooter),
ensuring the pins are lined up correctly and not stressed.
2. Connect the Battery Charger to the Mains power (240Vac) and Turn ON.
(b) Switch the Battery Charger ON and the Charger will automatically start.
(Note: If the Fault Indicator LED illuminates Red, please check your connections.
Refer to Trouble Shooting Page / LED STATUS INDICATOR TABLE for further
information)
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PX-2404M User’s Manual - Rev 1.6
The Charging process
The charging stages are as follows:
●Soft start:
Charges the battery using half the maximum current until the battery
voltage is over 23V. (LED Colour - ORANGE)
(Soft Start occurs if the initial voltage is less than 23V)
●Bulk Charge:
Charges using a constant maximum current (4A) until the
battery rises to the absorption level. (LED Colour - ORANGE)
●Absorption:
This stage charges the battery using a constant voltage of 29.0V
until the Battery Capacity is over approximately 85%.
(LED Colour - ORANGE)
●Fully Charged:
Battery is fully charged. It will be maintained at a safe constant
voltage. Float Voltage: 27.4V
(LED Colour - GREEN)
3. Disconnecting the Battery charger from Battery.
(a) Switch the Battery Charger OFF then Switch the Mains Power OFF and remove the AC
Power Socket from the outlet.
(b) Disconnect the Battery Charger fly lead from the battery.
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PX-2404M User’s Manual - Rev 1.6
LED STATUS INIDICATOR TABLE
A.C. Power Off / Switch is OFF / Battery Disconnected
Charging
Fully Charged (Float Charging)
Output lead short / reverse polarity
Soft Start Charge Time Out
Bulk Charge Time Out
Overheat Protection Mode
Weak / Faulty Battery
Fault
Red
OFF
OFF
OFF
Flash (1)
Flash (2)
Flash (3)
Flash (4)
ON
Charging
Amber
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
Full
Green
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
CHARGING CURVE (VOLTAGE)
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PX-2404M User’s Manual - Rev 1.6
TROUBLE SHOOTING
Problems
Charger does
not work
Indication
Indicator
lights are not
on
Charger has
no DC output
Fault LED
is Flashing.
No Charging
Current
Fault LED
is ON
Long
charging
time, Full
light does not
come on
Fault LED
is ON
Possible causes
- No AC power
- Output is short circuited
- Output cables are not
connected to the battery.
- Output Reverse polarity
connection
- Battery is severely sulphated
- Battery has a damaged cell
- Overheat protection mode
- Battery capacity too large
- Battery is defective
- 4 hours Soft Start timed out
- 16 hours Bulk Charge timed out
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Suggested solution
- Check AC connections and make
sure Power Point and Charger is
switched ON
- Check that there are no foreign
objects inside the XLR connectors.
- Check that the XLR plugs have been
securely connected.
- Check that the XLR plugs have not
been forced together incorrectly.
- Check the Battery condition, age etc.
- Battery may need replacement.
- Move battery & Charger to cooler
environment
- Check the charger specification
matches the battery capacity.
- Battery cannot be charged and must
be replaced.
PX-2404M User’s Manual - Rev 1.6
SPECIFICATIONS
Normal
Withstand
Unit
220-240
200~260
Vac
50/60
47-63
Hz
Unload input current :
80
max.
mAac
1-4
Input current consumption at 240Vac input, output 27.0V 4A loading
1.0
±10%
Aac
1-5
Nominal efficiency: at 240Vac input, output 27.0V 4A
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Charging Output Control Characteristics
2-1
Soft Start → Bulk Charge → Absorption Charge → Float Charge (Full)
2-2-1
Soft Start – start conditions:
6
±0.5
Vdc
2-2-2
Soft Start output current controlled:
2-3
±0.5
Adc
2-2-3
Soft Start mode transits to Bulk mode when battery voltage is above:
24.0
±0.5
Vdc
2-2-4
Soft Start charging time limited: Stop charging if battery voltage cannot reach 24.0V
4
±0.5
Hours
2-3-1
Bulk charging current controlled:
4
±0.2
Adc
2-3-2
Bulk charging time( Tcc ) limited:
16
±0.5
Hours
2-4-1
Absorption Mode charging output voltage controlled:
29
±1%
Vdc
2-4-2
Absorption mode transits to Float mode conditions:
8
±0.5
Hours
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AC Power Input Characteristics
1-1
Input voltage :
1-2
Input frequency :
1-3
>80%
1) Maintains charge until current drops by less than 0.1A over a 1 hour period.
2) Maintains charge for 2.5 hours until the charging current drops by less than 0.5A.
2-4-3
Absorption maximum charging time(Tcv) limited: (Force to Float mode when
Time-out)
2-5-1
Float charging output voltage controlled:
27.4
+/-1%
Vdc
2-5-2
Maximum Float charging current controlled:
2.0
±0.2
Adc
2-5-3
Float charging time limited:
0.5
±0.2
Hours
2-5-3
Restarts to Bulk charging when the battery voltage is below:
25.6
±0.5
Vdc
2-6
Unload output voltage when disconnected to the battery :
0.5
Max.
Vdc
2-7
Output short-circuit current when disconnected to the battery :
1
Max.
mAdc
1
Max.
mAdc
Battery flow back current (to the charger) when connected to 24V battery, AC Power
2-8
disconnected :
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Safety & Protection
3-1
Built in Temperature Protection.
3-2
Output Short Circuit Protection, Reverse Polarity Protection
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Electrical Parts
4-1
Input Connector
6 feet VDE H03VVH2-F 2X0.75mm2 with 2PIN SAA plug.
4-2
Out Put Connector
5 feet - XLR Type Connector
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Physical Parameters
5-1
Plastic Enclosure Dimensions
190(L) x 92(W) x 55(H) mm
5-5
Net weight :
approx. 860g
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Environmental Characteristics
6-1
Operating temperature :
0 to 45 oC
6-2
Storage temperature :
-25 to 85 oC
6-3
Operating Humidity range :
0 to 90% RH
6-4
Cooling:
Passive / Natural
* Specifications subject to change without notice
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PX-2404M User’s Manual - Rev 1.6
2 YEAR MANUFACTURER WARRANTY
D.C. Solutions Australia Pty. Ltd. (PowEx) warrants to the Customer that this product is
substantially free from defects in materials and workmanship under normal use for a period of 2
Years from the Date of Purchase.
Please ensure you keep a copy of your receipt on file as this will be required for proof of purchase
and 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 PowEx service centre through one of
the following methods:
Hotline: (03) 9482 2203
Website: www.dcsolutionsaustralia.com.au
If the Authorised Supplier and / or PowEx 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. 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 D.C. Solutions
Australia Pty. Ltd. (PowEx) accepts no responsibility / liability for goods lost or damaged in transit.
Return Shipping costs to be incurred by the Customer.
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, physical abuse, water damage, unauthorised attempts to open, repair
or modify the product or improper installation, this will not be covered under this warranty.
This Warranty is void if:
1. The product has been tampered or repaired by unauthorised personnel.
2. If connected to generator power without using surge protector
3. The warranty seal is broken or altered.
4. The warranty period has expired.
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PX-2404M User’s Manual - Rev 1.6
PX2404M Owners Manual
Website: www.dcsolutionsaustralia.com.au
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PX-2404M User’s Manual - Rev 1.6