BATTERY CHARGER

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6 – 9 – 12 – 24 - 48 V / 30A

ABVOLT TECHNOLOGIES INCORPORATED

MUMBAI
THEORY

General :

A battery charger or rechargeris a device used to put energy into a

secondary cell or rechargeable battery by forcing an electric current through
it.The charging protocol depends on the size and type of the battery being
charged.

Some battery types have high tolerance for overcharging and can be recharged by
connection to a constant voltage source or a constant current source; simple
chargers of this type require manual disconnection at the end of the charge cycle, or
advance chargers may have a timer to cut off charging current at a fixed time. Other
battery types cannot withstand long high-rate over-charging and hence require
advance battery chargers with temperature or voltage sensing circuits and a
microprocessor controller to adjust the charging current, and cut off at the end of
charge.

A trickle charger provides a relatively small amount of current, only enough to

counteract self-discharge of a battery that is idle for a long time. Slow battery
chargers may take several hours to complete a charge; high-rate chargers may
restore most capacity within minutes or less than an hour, but generally require
monitoring of the battery to protect it from overcharge. Electric vehicles need high-
rate chargers for public access; installation of such chargers and the distribution
support for them is an issue in the proposed adoption of electric cars.

About the Unit :

The Battery Charger provided is a simple basic type of Battery Charger used
to charge Lead Acid Batteries

The circuit used is of a simple multi output (6 – 9 – 12 – 24– 48 V / 30A)

battery charger for Lead Acid battery.
It gives various outputs of 6, 9, 12, 24& 48 volts upto30Amps current for
charging of the battery. If the battery is partially discharged, full charge will be
attained faster.\
The circuit uses a Multi Tap StepDownTransformer with switching and
necessary rectifier circuit to convert AC to DC. Since pulsed DC is good for Lead
Acid battery, a low value smoothing capacitor is used.To monitor the Voltage &
Charging status, digital Voltmeter andAmmeter are provided. A Voltage Selector
Switch to select Output Voltage and a MCB for Mains On / Off & safety is provided.

Select voltage according to your requirement by rotating the rotary switch and
take DC output of 30A (Max).
IMPORTANT SAFETY INSTRUCTIONS

Read Rules for Safe Operation and Instructions Carefully

Working in vicinity of a lead-acid battery is dangerous.
Batteries generate explosive gases during normal battery operation.
For this reason, it is of utmost importance that each time before using your charger,
you read this manual and follow the instructions exactly.

Before you use your battery charger, be sure to read all instructions and cautions
printed on:

• Battery Charger and its manual

• Battery and its manual

• Vehicle or unit using battery

Use battery charger on LEAD ACID type rechargeable batteries only, such as used
in autos, trucks, tractors, airplanes, vans, RV's trolling motors, etc.

Charger is not intended to supply power to low-voltage electrical system other than
in an automotive application.

WARNING: Do not use battery charger for charging dry-cell batteries that are
commonly used with home appliances. These batteries may burst and cause injury
to persons and damage to property.

The Battery Charger is intended for indoor use only. Do not expose to sunlight, rain,
snow or dampness.

Keep the manual in a safe and easily accessible place

Switch OFF before Connecting / Disconnecting the Unit from Mains

Switch OFF the Unit, prior to connecting the battery at output

Use proper Capacity Cable to interconnect Output to Battery

Batteries generate explosive gases during their normal operation. Never smoke or
allow an open spark or flame in the vicinity of the battery

Before using the charger, read and follow the batteries’ and any other involved
equipment’s safety, installation instructions and cautionary markings

Never attempt to charge a frozen battery

Remove watches, bracelets or anything of that nature before working on the charger

Do not touch any uninsulated parts or components when the power is ON

Someone should be within range of your voice or close enough to come to your aid
when you work near a leadacid battery

Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes

Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery

If battery acid contacts skin or clothing, wash immediately with soap and water

If acid enters eye, immediately flood eye with running cold water for at least 10
minutes and get medical attention immediately.

Do not install the charger/rectifier over a battery or a combustible surface

Do not obstruct the ventilation openings or the airflow space. Provide and ensure the
appropriate ventilation

Servicing should be attempted by an authorized, qualified & experienced technician

only. Do not start servicing the unit until at least five minutes have elapsed after
turning it OFF and disconnecting all AC and DC supplies

Charging a Battery

CAUTION: A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION.

TO REDUCE RISK OF A SPARK NEAR BATTERY

1. Check polarity of battery posts.

POSITIVE (POS, P,+) battery post usually has a larger diameter than NEGATIVE
(NEG, N,–) post.
2. Attach a cable (not provided) to the NEGATIVE (NEG, N, –) battery post. This
cable must be a minimum of 24” long, and of a wire gauge of proper capacity.
3. Connect POSITIVE (RED) cable &charger clip to POSITIVE (POS, P, +) post of
battery.
4. Position yourself and the free end of the cable (installed in step #2) as FAR away
from the battery as possible. FACING AWAY FROM THE BATTERY, connect the
NEGATIVE (Black) charger clip to the free end of the cable.