OZ Charge OC2406U Owner's Manual

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RED
CONNECTION IN VEHICULE
(NEGATIVELY EARTHED)
BLACK
BLACK
CONNECTION IN VEHICULE
(POSITIVELY EARTHED)
RED
Model: OC2406U
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 24 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
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The charger is designed to charge and maintain 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
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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
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Patented battery rejuvenation (reconditioning).
Battery voltage retention analysis.
Pulse charge for long term maintenance.
Ultra lower power consumption (ECO Mode)
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BLACK
RED
BLACK
Multi Stage:
1 - Qualification - Battery condition check
2 - Battery rejuvenation (recondition mode)
CONNECTION IN VEHICULE
CONNECTION IN VEHICULE
3 - Soft
startEARTHED
charging
(POSITIVELY EARTHED)
(NEGATIVELY
)
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
crocodile clip harness. If you require an optional ring terminal harness, please visit our website
www.ozcharge.com.au or contact your local reseller.
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
www.ozcharge.com.au
TEMPERATURE & SAFETY PROTECTION:
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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:
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Suits 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.
OC2406U
Charge Rate:
1A
4A
6A
Charging
3 - 20Ah
12 - 80Ah
18 - 120Ah
Maintaining
< 100Ah
< 120Ah
< 180Ah
3 • Oz Charge manual
www.ozcharge.com.au
ELECTRICAL PARTS & ACCESSORIES:
AC Power Cord:
1.8m with SAA 3 Pin AU Plug
DC Output Lead:
1.2m with quick connect
Charging Leads:
Quick connect 60cm Crocodile Clip Harness
TECHNICAL SPECIFICATIONS:
Model Number
OC2406U
Output
6A @ 24V
Input Voltage
220-240Vac / 1.8A(175W)
Input Frequency
50/60Hz
Charge Voltage
Gel - 28.2V
AGM&WET - 28.8V
Calcium - 29.4V
Equalising Voltage
Gel - 28.6V
AGM&WET - 29.2V
Calcium - 31V
Float Voltage
27.2V
Start Voltage
5V
Operating Temperature
-15 to 50° C
Storage Temperature
-25 to 85°C
Operating Humidity
90% RH Max.
Size (L*W*H)
214mm x 103mm x 55mm
Weight
1.1kg
Approvals
CE, UL/cUL, AS/NZS, EMC
CHARGING INSTRUCTIONS:
STEP 1 - Pre charge check & electrolyte level check
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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
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RED
RED
If the Battery is out of the vehicle:
- Connect the Red (+) Crocodile clip or optional
RED
ring terminal to the (+) battery terminal.
- Connect the Black (-) Crocodile clip or optional
ring terminal to the (-) battery terminal.
BLACK
BLACK
BLACK
BLACK CONNECTION IN VEHICULE
(NEGATIVELY EARTHED)
RED
CONNECTION IN VEHICULE
(POSITIVELY EARTHED)
RED
BLACK
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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
BLACK
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
CONNECTION IN VEHICULE
carburettor or fuel lines.
(POSITIVELY EARTHED)
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.
CONNECTION IN VEHICULE
(POSITIVELY EARTHED)
STEP 3 - Connect the battery charger to Mains Power (240Vac)
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The charger will automatically start when AC power is connected and switched on.
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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 charging. For Example do not charge a Gel Battery on the Calcium Battery Type setting as this may
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
BLACK
RE
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 32V maximum. If the battery voltage
doesn’t reach 18V 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
22V. If the battery voltage doesn’t reach 22V 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 28.2/28.8/29.4V.
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 22 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
27.2V.
6 • Oz Charge manual
www.ozcharge.com.au
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
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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.
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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)
LED STATUS INDICATOR TABLE:
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-003
OC2406U Owner’s Manual: Rev 1.0 - 12/14 - Specifications subject to change without notice.