6/12/24V 40A 8 STAGE AUTOMATIC WORKSHOP CHARGER & BATTERY MANAGER P/No.
IMPORTANT SAFETY INFORMATION Please read this manual thoroughly before use and store in a safe place for future reference. WARNINGS • Explosive gases. Prevent flames and sparks. Provide adequate ventilation during charging. • Before charging, read the instructions. • For indoor use. Do not expose to rain. • For charging lead acid batteries ONLY (of the size & voltage specified in the specifications table). • Always charge the battery on the correct voltage setting.
INDEX 1. Features Page 4 1.1 Specifications Page 6 1.2 Product Overview Page 7 1.3 Assembly/Set Up Page 9 2. Operation Page 10 2.1 Setting Battery Voltage Page 11 2.2 Pulse –Tronic Charge Page12 2.2.1 Charge Function Modes Page 12 2.2.2.1 Storing Pulse-Tronic Charge Page 14 2.2.2.2 Storing Supply/Diagnostic Mode Page 14 2.3 Battery and Alternator Test Page 15 2.3.1 Battery Test Page 15 2.3.
1. FEATURES AUTOMATIC 8 STAGE CHARGING Automatic 8 stage charging delivers a complete and thorough charge giving your batteries longer life & better performance. Once the battery is fully charged, the battery charger will continue to monitor the battery without the risk of overcharging.
AUTO/MANUAL ADJUSTABLE OUTPUT Manually or use the Automatic charge setting feature to adjust the rate of charge to best suit different battery sizes. MULTI VOLTAGE OPERATION Suitable for charging 6V, 12V & 24V batteries. SHORT CIRCUIT & POLARITY PROTECTION POWER SUPPLY MODE Supply Power to the vehicle whilst the battery is being changed. DIAGNOSTICS POWER SUPPLY Supplies stabilised power to the vehicles MCU whilst receiving software updates.
1.1 SPECIFICATIONS P/No. HDBM4000 6V 12V 8 Stage Automatic Input 240V, 50Hz, 600W Output Engine Start Minimum Start Voltage 3-40A 3-40A – 70A for 3 sec – 2.0V 2.0V 2.0V 3-20A Charge Voltages (Absorption) AUTO 7.2V 14.4V 28.8V AUTO i 7.7V 15.4V 30.8V GEL 7.2V 14.4V 28.8V AGM 7.35V 14.7V 29.4V WET 7.7V 15.4V 30.8V Calcium 8.0V 16.0V 32.0V Float Voltage 6.7V 13.5V 27.
1.2 PRODUCT OVERVIEW Figure A 1 2 3 4 5 20 19 18 6 17 16 15 14 13 12 11 10 21 22 9 8 7 23 1. 2. Display of the set battery voltage value. Main display. Display: measured battery voltage, current, Ah selection, voltage value selected for the Supply / Diagnostic / Equalization programs, interface messages for the operator, alarm codes. 3. Polarity inversion, short circuit, worn out or faulty battery alarm. 4. Set current, voltage and Alarm codes“AL1 - AL9” 5. Battery charge level. 6.
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 8 Choice of the battery production technology: WET: lead-acid batteries with liquid electrolyte; GEL: lead-acid batteries, sealed, with solid electrolyte; AGM: lead-acid batteries, sealed, with electrolyte on absorbent material; PbCa: lead-calcium batteries. SUPPLY mode. DIAGNOSTIC mode. PULSE TRONIC charge process phases. START mode. Automatic charge mode. Pulse Tronic charge. Alternator Test Function.
1.3 ASSEMBLING CHARGING LEADS TO BATTERY CLAMPS The HDBM400 battery charger is shipped with the battery clamps disconnected from the positive & negative charging leads. IMPORTANT: • The negative (Black) battery clamp must be connected to the charging lead with the black heat shrink on the lug. • The positive (Red) battery clamp must be connected to the charging lead with the red heat shrink on the lug. To connect both the positive and negative leads to the battery clamps refer to the instructions below: 1.
INITIAL CONDITION ò DEVICE OFF Keep pressed the button “Battery Voltage” and plug into mains socket. Release button “Battery Voltage” after 7”. BATTERY VOLTAGE + 7” 230V - 1ph 50/60 Hz CABLE CALIBRATION DISPLAY 7” BEEP DISPLAY BATTERY VOLTAGE 2. OPERATING INSTRUCTIONS Follow the instructions in the order given below. 1. Remove the battery covers (if present), so that the gas produced during charging can exit.
a. Make sure the level of electrolyte covers the battery plates; if they are not covered, add distilled water until they are submerged by 5–10 mm. ATTENTION! BE VERY CAREFUL WHILE CARRYING OUT THIS OPERATION BECAUSE THE ELECTROLYTE IS AN EXTREMELY CORROSIVE ACID. 2. Check the polarity of the battery terminals: the (+) symbol is positive, the (-) symbol is negative. 3. Connect the red clamp to the positive terminal on the vehicle battery (+ symbol). 4.
2.2 PULSE-TRONIC CHARGE 2.2.1 CHARGE FUNCTION MODES There are various Pulse Tronic charge procedures that depend on the battery construction technology (T) and the charge current (C). When the battery is charged, the battery charger switches automatically to maintenance mode.
c) CUSTOMISED PULSE-TRONIC It is possible to select: – the battery construction technology (fig. A.11)choosing between:“WET, GEL, AGM, PbCa” – the charge current (fig.A.6) choosing between:“AUTO” - automatic setting according to battery conditions;“BOOST” - rapid charge; – the Ah - customised setting of the battery Ah (fig.A.2) using 6 predefined values selected using the “CHARGE RATE” button (fig. A.23), adjustable at 5 Ah intervals using the “BATTERY VOLTAGE” button (fig. A.
END OF CHARGE – EXAMPLE CHARGE COMBINATION CHART Battery Type (T) Battery Current (C) AUTO Auto Auto Boost Manual ‘Ah’ AUTO i Auto Auto Boost Manual ‘Ah’ WET, GEL, AGM, PdCa Auto Auto Boost Manual ‘Ah’ 2.2.2 CHARGE FUNCTION MODES It is possible to store the last function modes, so they are immediately available after any switching ON/OFF. 2.2.2.1 STORING PULSE-TRONIC CHARGE Storage of voltage and type of battery, charge mode.
2.3 BATTERY AND ALTERNATOR TEST The measurements can be performed with the battery connected to the vehicle, after connecting the clamps. Select the measurement to be performed using the “MODE” button (fig. A.22). On completing the test(s) disconnect the power cable from the mains socket and disconnect the clamps from the battery terminals. NB: it is only possible to perform the tests without a power supply if the tests type selection is made after connecting the clamps to the battery terminals. 2.3.
2.3.2 CHARGE SYSTEM TEST (ALTERNATOR) Measure the voltage of the batery terminals. ALTERNATOR TEST SELECTION MODE DISPLAY Procedure – press the “MODE” button (fig. A.22) to select this function (fig. A.18); the message “Bad”appears on the display (fig. A.2); – connect the clamps to the battery terminals; – press the “BATTERY VOLTAGE” button (fig. A.21) to select the battery voltage (fig. A.1); – switch on the engine, taking it to approx.
2.3.3 BATTERY STARTING CHARGE CAPACITY (CCA) Measure the voltage of the batery terminals. CCA TEST SELECTION MODE DISPLAY Procedure – press the “MODE” button (fig. A.22) to select this function (fig. A.19); – connect the battery terminal clamps, the message“Go” appears on the display (fig. A.2); – press the “BATTERY VOLTAGE” button (fig. A.21) to select the battery voltage (fig. A.1); – start the engine; – check the display (fig. A.
2.4 BATTERY MAINTENANCE The device has two advanced operating modes for the maintenance of 6/12/24V batteries (ADVANCED PROGRAMS), press and hold the “MODE”button for 3 seconds (fig. A.22) recommended for AGM and WET type batteries: – DESULFATION: recovery of sulphated batteries (fig. A.10); – EQUALIZATION: reset of optimal battery conditions (fig. A.9).
3" BEEP 2.4.1 DESULFATION Pulse system used to recover sulphated batteries by applying enough voltage to neutralise the surface layers of oxide and revitalize the underlying plates. It is advisable to perform this operation with the battery disconnected from the vehicle. FUNCTION SELECTION MODE DISPLAY ATTENTION! Pay particular attention to the nominal voltage of the battery which must correspond to the battery selected using the “BATTERY VOLTAGE” button and indicated on the display (fig. A.1).
ATTENTION! Pay special attention to the type of battery being equalized (WET, GEL, AGM, PbCa): check the maximum allowed voltage to avoid damagingFUNCTION the same. SELECTION MODE Customising the VOLTAGE DISPLAY To customise the equalization voltage value simultaneously press and hold the “BATTERY VOLTAGE” (fig. A.21) and “MODE” (fig. A.
BEEPEND Info OF PROCESS – EXAMPLEAlarm 2.5 POWER SUPPLY The device foresees 2 operating modes (ADVANCED PROGRAMS) as a generator stabilised at 6/12/24V: – DIAGNOSTIC (fig. A.13); – SUPPLY (fig. A.12). Info BEEP Alarm ADVANCED MENU SELECTION MODE MENU ADVANCED PROGRAMS BEEP MENU SELECTION 3" ADVANCED MODE On completing the selected process, disconnect the power cable from the mains MENU socket and disconnect the clamps from the battery terminals. ADVANCED KEYBOARD LOCK BUTTON LOCK.
2.5.1 DIAGNOSTIC Disturbance free precision power for supporting the battery during the vehicle electric system diagnostic operations (function used mainly in workshops). FUNCTION SELECTION MODE DISPLAY The set voltage is present on the charge clamps when connected to the battery. NOTE. The battery must not be disconnected from the vehicle (so as not to lose the setup settings) and must have a minimal voltage of 5V to guarantee the correct functioning of the process.
13.1V ..... 13.5V CURRENT – press the “CHARGE RATE” button (fig. A.23) until the desired value, set as indicated in step 6, appears on the display (fig. A.4) and on the icon (fig. A.6). The set current mode will be exited automatically after a 3” time-out. CURRENT ADJUSTMENT – EXAMPLE CHARGE RATE ► 3A 7A 10A 20A 30A 40A 3A 7A 10A 20A 30A 40A PROCEDURE – press the “MODE” button (fig. A.22) to select this desired function (fig. A.13 or fig. A.
Customising VOLTAGE and CURRENT VOLTAGE FUNCTION SELECTION – press and hold simultaneously the “BATTERY VOLTAGE” (fig.A.21) and “MODE” FUNCTION SELECTION MODE buttons 3 seconds MODE(fig. A.22) forDISPLAY – use the same buttonsDISPLAY to select (decrease using the “BATTERY VOLTAGE” button and increase using the “MODE” button) the desired voltage value between 6V-7.5V, 12V-15V, 24V-30V respectively for 6V, 12V, 24V batteries; the factory default voltage value is respectively 6.8V, 13.6V,27.2V.
2.6 ENGINE START – START START mode (fig. A.15), is available for 12V batteries and supplies 70 A current as a starter aid. If the battery is completely run down, it is advisable to perform a precharge cycle before proceeding. FUNCTION SELECTION CHARGE RATE DISPLAY 3" 2.6.1 Procedure FUNCTION SELECTION – Press and hold the “CHARGE RATE” button (fig. A.
2.7 ALARMS The alarms are displayed by a graph symbol (fig. A.3) when there is reverse polarity, short circuit, low or faulty battery. The alarms will appear on the display (fig. A.2) and have the following meanings: AL1: Reverse polarity and short circuit; AL2: Battery voltage incompatible with selection; AL3: PULSE TRONIC charge: has not completed the Desulphation within the 4 hour time limit, battery may not be recoverable.
3 FREQUENTLY ASKED QUESTIONS Q. Why does the LCD screen indicate a fully charged battery straight away? A. There are two possible reasons why the LCD display may indicate a fully charged battery (‘OK’) straight away. 1. The battery is fully charged. 2. The battery has taken a surface charge. Q. What is Surface Charge? A. Batteries unused or left flat for some time build up a resistance to being recharged.
