PART NO G4106
HANDBOOK
Gunson Automatic Battery Charger
Fully Automatic Battery Charger
For Maintenance Free and other Sealed Batteries
CONTENTS
Page
1. PRECAUTIONS
4
2. GENERAL INFORMATION
5
3. COMMENCING CHARGING
6
4. DURATION OF CHARGING
7
5. AFTER CHARGING
7
6. FURTHER TECHNICAL NOTES
8
A. PRINCIPLE OF OPERATION
B. PROTECTION
C.TESTING THE BATTERY CHARGER
7. SIGNS AND SYMPTOMS
10
A. CHARGE RATE NEVER REACHES ZERO.
B. CHARGE RATE NEVER VERY HIGH.
C. CHARGE RATE ZERO, BATTERY FLAT.
D. CHARGER RAPIDLY SWITCHING BETWEEN
MAXIMUM CHARGE RATE AND ZERO.
E. INITIALLY HIGH CHARGE RATE, SOON FALLING TO ZERO.
F. CHARGE RATE VERY HIGH AND REMAINS VERY HIGH
G.AMMETER POINTER PULSES ON AUTOMATIC
MODES,WHEN NEARING FULL CHARGE.
H.TECHNICAL SPECIFICATION
8. GUARANTEE
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3
Gunson Automatic Battery Charger
1. PRECAUTIONS
•
Battery chargers are high powered items of electrical equipment, and each year
national accident statistics show that domestic battery chargers are involved in
several accidents, including fire incidents. Gunson's battery chargers include various
safety features and internal overheating protection devices, but to guard against
possible hazards, however unlikely, it is important that the user reads the following
precautions:
•
The battery charger should be stood on a flat, level, surface. Ensure no flammable
materials (wood, paper, and fabrics) are near the charger. Do not obstruct
ventilation holes in the top, base or side of the charger. Adequate ventilation is very
important for correct operation, and also to reduce the possibility of overheating in
the event of internal malfunction.
•
Use only in an area free from flammable vapours (petrol, paint etc.) and well
ventilated to aid the dispersal of any gasses and fumes that may be generated by the
battery. Even with automatic charging, some "gassing" (i.e. the emission of
inflammable/explosive gases) can occur, particularly if the battery is faulty or
becomes faulty during charging.
•
Do not operate the charger for extended periods in an overloaded state. Ensure the
charger is operating within its rated continuous charge before leaving it
unattended. Overloading may initially occur with a large totally flat battery and may
occasionally happen with a faulty battery where the battery draws a continuous
very high current from the charger.
•
Do not operate the charger with the leads to the battery reversed.
•
Under no circumstances should the user open, modify or attempt to repair the
charger. In particular, an internal fuse is not user replaceable. It is intended as a fail
safe device in the event of other component malfunction.
•
If used to charge a battery connected to a vehicle, make absolutely sure that all
electrical load is "OFF" and connect only as follows:
Connect the appropriate charger output lead to the battery power connection
(usually +). Connect the other charger lead to ground on the chassis/engine away
from the fuel lines and battery vents. Connect to the main ac power supply. After
charging remove ac power supply, ground connection and the connection to the
battery power in that order. Note also the vehicle manufacturer’s instructions.
Before the battery is disconnected check you have codes for audio, security system
etc. or use a device similar to Gunsons Vehicle Memory Saver to retain all codes and
system settings.
•
Battery electrolyte is a corrosive acid. On accidental contact, rinse with plenty of
cold water. Also for eye contact always seek medical attention.
•
This charger is mains equipment not designed or intended for use outdoors in
adverse conditions. Do not expose it to damp, rain or snow.
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Gunson Automatic Battery Charger
•
This charger is not suitable for NICAD batteries or other batteries that work on
some principle other than lead/acid. Motor car batteries are invariably of the
lead/acid type.
2. GENERAL INFORMATION
CONFORMS TO BS/EN: 60335-2-29, 50081-1, 50082-1
This battery charger is particularly suitable
maintenance-free and other sealed batteries that
normal (non-automatic) battery charger. Such
"dry-fit", or have gel electrolyte. It is also suitable
are commonly used in the following applications:
•
for use with 12 volt lead/acid
may be damaged by the use of a
batteries may be referred to as
for 12 volt lead/acid batteries that
MOTOR CARS AND MOTORCYCLES ? GOLF CADDIES ? ELECTRIC INVALID
WHEELCHAIRS ? CAMPING, CARAVANNING ? SAILING, POWER BOATING
These applications use the battery for starting or as a primary power source, where it
is repeatedly discharged and recharged (eg golf caddies, electric wheelchairs, power for
lighting/TV while camping/caravanning). If there is any doubt about the suitability of
this charger, consult the battery specifications or contact the battery
manufacturer. This charger can also be used to provide a maintenance charge,
generally referred to as a "float" charge. Typical applications where a charger is left
connected for long periods or where a vehicle, boat, or caravan is used infrequently, or
laid-up.
Note that this charger is not approved for being built-in to or connected as a
permanent fixture to a caravan.
In some applications, such as camping and caravanning, the user may wish to be
charging the battery at the same time as using it to supply power. This is only
acceptable provided that total current draw is always below the rated continuous
output of the charger (4.2 Amps DC). For higher current draw, the internal "Thermal
Cutout" device may periodically be operating to allow the charger to cool down. The
thermal cutout device is intended as a safety feature to protect against overheating,
and it is not intended to be called into play in regular use, which may reduce its life, and
increase the hazard of overheating.
The advantage of this automatic battery charger when compared to a normal
(non-automatic) battery charger is that it will reduce its charge rate to zero as the
battery reaches full charge giving the following benefits:
•
•
•
•
•
•
•
•
ESSENTIAL FOR SEALED BATTERIES?
NO DANGER OF OVERCHARGE
NEGLIGIBLE LOSS OF ELECTROLYTE BY "GASSING"
ELIMINATED SPLASHES OR "FIZZING" OF ACID SPRAY
NEGLIGIBLE EMISSION OF EXPLOSIVE GASSES
AVOIDANCE OF NASTY SULPHUROUS SMELLS
EASY TO SEE WHEN A BATTERY IS FULLY CHARGED
WILL SOMETIMES IDENTIFY A FAULTY BATTERY
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Gunson Automatic Battery Charger
Since there is negligible emission of gases, it follows that the charger can be used on
sealed batteries, and that the filler caps of unsealed batteries do not have to be
removed before charging, hence reducing the danger of spilled acid. This means that it
is not necessary to remove a battery from the car for charging. On the other hand,
this battery charger offers the facility of being able to switch the automatic feature off.
This is useful when beginning to charge some batteries that are dead flat, particularly
those that have been flat for some time.
Warning: switching the automatic feature off renders the other switch inoperative, and
eliminates the above benefits.
3. COMMENCING CHARGING
If the battery is installed see PRECAUTIONS. Ensure that the charger is switched off
at the mains supply. Connect the positive lead of the charger (RED) to the battery positive terminal (usually indicated by + or P) and the battery charger negative lead
(BLACK) to the negative terminal of the battery (usually indicated by - or N).
Set the switches on the front of the charger according to the way the battery is used.
If the battery is flat or partly charged, set "AUTO ON" and "100% CHARGE". If the
battery is flat, and is merely to be partly charged as quickly as possible in order, for
example, to start a car engine with a minimum of delay, then set "AUTO OFF". If the
battery is to be charged while in use to supply a small load or to be float charged, then
set "AUTO ON" and "PERMANENT FLOAT". If the battery is dead flat, such that it
will not accept a charge, then set "AUTO OFF" until charging commences and a
reasonable charge rate is seen on the ammeter, then revert to the "AUTO" switch
setting. (NOTE: The switches can be changed while the charger is in operation). The
chart below can be used as a general guide.
Connect the battery charger to the main ac supply and switch on. The charger should
CAR BATTERY - NORMAL
RECHARGE
GOLF CADDY / POWER
WHEEL CHAIR
AUTO
100%
ON
CHARGE
CHARGING WILL
NOT BEGIN
AUTO
100%
FASTEST CHARGE
ON
CHARGE
RATE
BOATING / CARAVANNING/
CAMPING - CYCLIC
AUTO
100%
ON
CHARGE
AUTO OFF
INITIALLY
BOATING / CARAVAN/
CAMPING - CONTINUOUS
AUTO
ON
PERM
FLOAT
AUTO OFF
ALL BATTERIES WHEN
VEHICLE LAID-UP
AUTO
ON
PERM
FLOAT
now be charging the battery. An indication of the rate of charge will be shown on the
ammeter.
Note that it is important to connect the leads to the battery terminals BEFORE
switching on the main ac supply. This is because in connecting "live" leads to a battery
sparks can be produced. Sparks can cause explosion or fire in the presence of petrol
and/or battery vapours. Similarly, always switch off at the mains before disconnecting
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Gunson Automatic Battery Charger
clips from the battery.
For a normal battery in otherwise good condition, but simply discharged or partially
discharged, the charge rate may be initially high (8 Amps DC or more), gradually falling
within a few minutes to a charge rate of typically 4 to 5 Amps DC (depending on
battery capacity). When the battery is nearing full charge, then the charge rate will
reduce. If an automatic mode has been selected, then the charge rate will eventually
reduce to zero.
The user should check that the charge rate does not remain at the very high initial
charge rate, which indicates a faulty battery or remains connected to equipment. It is
a prudent safety measure not to leave a battery charger unattended while it is
charging at a very high rate, even though the charger contains several fail-safe devices.
Note: Conventionally, all battery charger manufacturers quote battery charger output
in Amps RMS (EFF in the EEC), and this is the upper scale shown on Gunson's battery
charger dials. The equivalent Amps DC (ARITH in the EEC), which is the true
charging current for the battery, is shown on the lower scale.
4. DURATION OF CHARGING
Typically, the charger will require 15 to 20 hours to charge the average motor car
battery of size 35 - 43 ampere hours (Ah) from completely flat, and proportionately
less from other states of charge. Other sizes of battery will require proportionately
more or less time to become fully charged.
An indication of full charge when using the "AUTO ON" setting is when the charging
current has reduced to zero. Ignore any pulsing or vibrating of the ammeter pointer
on the AUTO ON setting, particularly as the charge rate approaches zero, or is zero, as
this is quite normal. If, on the "AUTO ON" setting, the charge rate never reduces to
zero, then this is an indication of a faulty battery.
When using the "AUTO OFF" setting, the meter may not indicate zero even for a fully
charged battery. The use of a hydrometer or a measurement of battery voltage or will
detect the level of battery charge. Gunson produce a range of multiple scale meters
which can be used for the purpose - Pocketmeter, Startcheck, Autoranger, Testune,
Digimeter etc. The onset of vigorous "gassing" is an indication that the battery is fully
charge. Uneven gassing in some cells indicates a battery problem.
5. AFTER CHARGING
When charging is complete, the charger may be disconnected, or may be left
connected in order to provide a float charge as required. If the battery is left
connected to the charger, switch to "AUTO ON" and "PERMANENT FLOAT". Under
these conditions it is wise to check the battery occasionally, a battery in good condition
will not be gassing as the voltage is regulated to 13.9V. A battery with a faulty cell may
behave as a 10V battery, it will be gassing because charging continues and float
charging is not advisable.
In order to disconnect the charger, switch off the main ac supply BEFORE
disconnecting the charger leads from the battery (this is to avoid any possibility of
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Gunson Automatic Battery Charger
sparks igniting battery gases).
Examine and clean the battery terminals and the battery lead terminals. Smear the
connections with Vaseline, re-connect the battery leads to the battery terminals, and
refit any protective boot covers.
6. FURTHER TECHNICAL NOTES
A. PRINCIPLE OF OPERATION
In its AUTOMATIC modes, this battery charger works on a similar principle to the
alternator of a motor car, that is, the voltage output of the charger is regulated so that
it never rises above the voltage level at which significant "gassing" of the battery
electrolyte occurs. "Gassing" is the electrolytic conversion of the water in the
electrolyte of the battery to the gases hydrogen and oxygen.
Gassing can rapidly deplete the level of the acid in the battery, leading to the
premature failure of sealed batteries, and the need for topping-up of unsealed
batteries. ("Gassing" is not to be confused with the occasional "gurgle" that will be
noticed on observation of a battery that is on charge or in use).
Unfortunately, there is a slight "overlap" between the charging voltage needed to fully
charge a battery, and the charging voltage needed to avoid all gassing. If a battery is to
be 100% fully charged, then a small amount of gassing has to be accepted. On the other
hand, the voltage that avoids all gassing will not totally charge a battery.
To fully re-charge a discharged battery, the voltage level is set at 14.5 volts (switch
settings "AUTO ON" and "100% CHARGE"). This will provide a full 100% re-charge,
while still giving negligible gassing (minor loss of electrolyte may occur after long
periods at this setting). Incidentally, the regulated voltage level of vehicle alternators
is generally around 14.5 volts. An absolutely full 100% re-charge is important in such
applications as golf caddies, electric wheelchairs etc, where less than 100% charge
would give a shorter operating time and might reduce the life of the battery.
To avoid all loss of electrolyte in extended periods of use, such as when the charger is
left connected to a fully charged battery for long periods, the voltage level is set at 13.9
volts (switch settings "AUTO ON" and "PERMANENT FLOAT"). With the switches in
this position, a fully charged battery will be maintained in the fully charged state, but a
flat battery would cease charging before it was completely charged. Under these
conditions, the output of the charger depends on the battery, but is typically a few
milliamps for a battery in good condition.
It should be noted that once a battery develops a fault (eg an internally shorted cell) it
may still "gas" even when the charger is set at "Permanent Float". Permanent
charging is then not recommended as the battery will deteriorate further with time.
The Voltage/Current characteristic of this charger in its single non-automatic and two
automatic modes are as shown in the following figure.This applies when the charger is
supplied at its full rated voltage.
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Gunson Automatic Battery Charger
B. PROTECTION
This charger is fully protected against customer misuse and overloading, including by
means of a self-resetting current/thermal cutout. This cutout will come into operation
if the current drawn from the charger exceeds its rated level under conditions as specified in BS/EN 60335. The cutout will automatically reset after a time that may be a
few seconds to several minutes, when battery charging will re-commence. Operation
of the cutout is quite normal, and may occasionally be observed in the early stages of
charging a battery, when the current draw can be quite high. However, in most
instances the charge current will have reduced to a low level before operation of the
cutout is required. High ambient temperatures, low ventilation, and high capacity batteries lead to cutout operation. This cutout will also provide reasonable protection
from inadvertent shorting together of the output leads of the charger, or connection
to the battery with reversed polarity. Such misuse should be avoided in spite of the
protection provided.
TECHNICAL NOTE: An internal fuse is fitted to provide protection against internal
component failure. This fuse is not user-serviceable, and should NOT be replaced. If
this fuse "blows" then the unit is unserviceable and should be returned to Gunson for
repair.
C.TESTING THE BATTERY CHARGER
The preferred test of whether the charger is operating is to connect the output clips
to a vehicle headlamp bulb and switch on at the main ac supply. The ammeter should
show an output (say 4A) and the bulb should light at almost full intensity. Brief
connection of the output leads is a more severe test of charger and cutout but should
only be continued for one cutout cycle maximum as this test imposes a severe strain
on the charger.The ammeter should swing to show full output, in less than a second the
thermal cutout should operate and the output fall to zero. After a further few seconds
the cutout should click back in, indicated by a return to full output.
A test of the automatic feature of the charger requires the use of an accurate voltmeter, such as Gunson's, DIGIMETER, POCKETMETER,TESTUNE or AUTORANGER.
The purpose of this test is to check the voltage output of the charger against the
characteristic shown in the figure above. Connect the charger to a battery and charge
the battery. As the battery is nearing full charge (ie the charge current is between 0.4
and 0.8A), connect the voltmeter across the terminals of the battery. With the
charger set to "AUTO ON" and "100% CHARGE", the voltmeter should read 14.5 +0.1.
The same test with the charger set to "AUTO ON" and "PERMANENT FLOAT"
should show a voltage of 13.9 +0.1. The output may not change instantaneously to the
above figures when switched, due to the stored charge in the battery.
If the charger passes these tests then it is performing correctly.
Note that the voltage test of the output can NOT be done without the charger
connected to a battery. Under open circuit conditions the voltage output is
meaningless and may only show 11V to 12V with"AUTO OFF".
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Gunson Automatic Battery Charger
7. SIGNS AND SYMPTOMS
A. CHARGE RATE NEVER REACHES ZERO.
With the switch set to "AUTO ON", the charge rate should fall to zero for full
charge. Failure to do this indicates a faulty battery. Note however that a very large
capacity battery can take several days to reach full charge.
B. CHARGE RATE NEVER VERY HIGH.
For a flat or partly charged battery, this is an indication of a faulty battery.
C. CHARGE RATE ZERO, BATTERY FLAT.
A dead flat battery can be difficult to start to charge, particularly if it has been
allowed to remain in the dead flat state for some time. Set "AUTO OFF" until
charging commences, then revert to the appropriate switch settings.
D. CHARGER RAPIDLY SWITCHING BETWEEN MAXIMUM CHARGE RATE AND
ZERO.
Incorrect connection, the leads from the charger being reversed. Or large flat
battery - soon reverts to normal charge.
E. INITIALLY HIGH CHARGE RATE, SOON FALLING TO ZERO.
Battery already fully charged, or battery faulty with low charge capacity.
F. CHARGE RATE VERY HIGH AND REMAINS VERY HIGH
A faulty battery is indicated, in which case charging should be discontinued to avoid
putting charger overload protection under stress. If the charge rate is high because
of some load connected to the battery, then this load should be disconnected.
G. AMMETER POINTER PULSES ON AUTOMATIC MODES, WHEN NEARING
FULL CHARGE.
This is normal operation.
H. TECHNICAL SPECIFICATION
INPUT: 240V -230V 50Hz
INSULATED
108W.
DOUBLE
OUTPUT AUTO ON OR OFF:9A RMS(EFF) 6 A DC 15/15 MINS
RMS(EFF) 4.2A DC CONTINUOUS
MAX VOLTAGE REGULATED 14.5+0.1 (100% CHARGE)
13.9+0.1 (PERMANENT FLOAT)
BATTERY 15Ah TO 65Ah RECOMMENDED
FULL OVERLOAD, REVERSE POLARITY
AND THERMAL CUTOUT PROTECTION
CONFORMS TO BS/EN: 60335-2-29, 50081-1, 50082-1
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7A
Gunson Automatic Battery Charger
8. GUARANTEE
This guarantee is in addition to the statutory rights of the purchaser.
The Tool Connection has made every effort to ensure that this product is of the
highest quality.
If this product should require service or repair at any time, it should be returned to:
The Tool Connection Limited,
Kineton Road Industrial Estate,
Southam,
Warwickshire.
CV47 0DR
For technical information please telephone: ++44 (0) 1926 818181
When sending goods for service or repair, please give full details of faults requiring
attention.
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