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4load Charge Box 7.0 User Manual

Made by: 4load
Type: User Manual
Category: Battery Charger
Pages: 11
Size: 2.77 MB

 

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WWW.4LOAD.DE

CHARGE BOX 7.0

Stand der Information: 09/2008

4 Load GmbH

Glendale Str. 4
87700 Memmingen
Germany
www.4load.de

BATTERY-CHARGER 7,0 AMP

USER MANUAL

 


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Table of Content

Introduction

For your safety ...........................................................................................Page  14

Intended use ..............................................................................................Page  14

Scope of delivery........................................................................................Page  14

Description of parts ....................................................................................Page  14

Technical data ............................................................................................Page  15

Safety

Safety information ......................................................................................Page  15

Properties .................................................................................................Page  16

Before starting device up for the first time

 ...................................Page  17

Operation

Connection ................................................................................................Page  17

Disconnecting ............................................................................................Page  17

Select mode of operation ............................................................................Page  17

State of charge ..........................................................................................Page  18

Trickle charging (13.6 V / SUPPLY) .................................................................Page  18

Regeneration mode (16 V BOOST) ................................................................Page  19

Impulse charging ........................................................................................Page  19

Charger protection function .........................................................................Page  19

Overheating protection ................................................................................Page  19

Memory function ........................................................................................Page  19

Average charging time.................................................................................Page  19

Maintenance

 ...........................................................................................Page  19

Disposal

 ...................................................................................................Page  20

Information

Servicing ...................................................................................................Page  20

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Introduction

Battery charger  

CHARGEBOX 7.0

q  

Introduction

q  

For your safety

   Read the directions for use through 

carefully. 

q  

Intended use

The CHARGEBOX 7.0 is suitable for charging and 

trickle charging 12 V and 24 V lead-storage batteries 

with electrolytic solution, AGM or gel. Use the charger 

in a well-ventilated room. The manufacturer is not 

liable for any damage arising from improper use. 

The device is not intended for commercial use.

q  

Scope of delivery

1  CHARGEBOX 7.0 charger

1  Power cable with mains plug

1  Charging cable with 2 connecting terminals

1   Charging cable with 2 ring terminals

1   Charging cable with 12 V plug

1   Storage bag (depending on the model)

1   Directions for use

q  

Description of parts

Q

 

 “Error”

W

 

 “Charging” (-25%)

E

 

 “Charging” (-50%) 

R

 

 “Charging” (-75%)

T

 

 Trickle charging (100%)

Y

  SUPPLY LED (“Electrical power supply”) 

U

  Regeneration mode (16 V BOOST)

I

  Maintenance mode (13.6 V / SUPPLY)

O

  “Mode 4” (14.7 V)

P

  “Mode 3” (14.4 V)

{

  “Mode 2” (29.4 V)

}

  “Mode 1” (28.8 V)

“MODE” button

w

  “POWER” display (ON / OFF)

e

  Charger

The following pictogrammes / symbols are used in these operating instructions:

Read the operating instructions!

W

Watts (effective power)

Always heed warning labels and  

safety instructions!

V~

Volt (AC)

Caution - Danger of electric shock!  

Hazardous voltage – danger to life!

A/Ah/

mA

Amps / Amp-hours / Milliamps

Explosive material!

Hz

Hertz (mains frequency)

Risk of fire!

Direct current

(Type of current and voltage)

Keep children and other people away from 

the battery charger during its operation.

Dispose packaging and appliance in an  

environmentally-friendly way!

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Introduction / Safety

r

  Power cable with mains plug

t

  Charging cable with 12 V plug

y

  “+”-pole connecting cable ring terminal (red)

u

  “–”-pole connecting cable ring terminal (black)

i

  “+”-pole alligator clip (red) 

o

  “–”-pole alligator clip (black)

p

  Connecting cable ring terminals

[

  Connecting cable connecting terminals

]

  Connection adaptor 

q  

Technical data

Primary

Rated input voltage: 

220 - 240 V ~ 50 / 60 Hz

Starting current: 

< 50 A

Rated input current: 

max. 1.2 A (actual value)

Power consumption:  

135 W

Secondary

Rated compensating  

voltage:     

 12 V 

24 V 

Charging voltage:  

 28.8 V / 29.4 V (±2%), 

14.4 V / 14.7 V (±0.25 V), 

 

 

   

13.6 V / 16.5 V (±0.25 V)

Charging current: 

 7 A (±10%), 5 A (±10%), 

3.5 A (±10%), 3 A (±10%),  

1.5 A (±10%)

Rated  

equalising current:  

3.5 A / 7 A

Ripple**:     

max. 150 mV

Reverse current*:  

< 5 mA (no AC input)

System of protection:    IP 65 (dustproof,  

waterproof)

Battery type:   

 12 V + 24 V-lead-acid  

batteries (AGM, GEL, MF, 

open and VRLA)

Battery capacity:  

 12 V : 14 Ah - 230 Ah /  

24 V : 14 Ah - 120 Ah

Fuse (internal): 

10 A

Noise level:   

> 50dB

Ambient temperature:  0 - +40 °C

Dimensions:   

200 x 80 x 50 mm (l x w x h)

*  =  Reverse current is the current that the charger 

uses from the battery when it is not connected 

to the mains current. 

**  =  Noise figure is the nuisance value of the current 

and voltage.

q  

Safety

  Safety information

J     

 Do not operate the appliance with a damaged 

cable, power cord or plug.

m   Caution! A damaged power cord causes 

danger to life by electric shock.

J     

 If damaged, have the power cord repaired by 

authorised and trained technicians only!

J     

   Do not allow toddlers or children near 

the charging station without super-

vision! Children cannot assess the 

 

 potential danger in the handling of electrical 

equipment.

J    

Children or persons who lack the knowledge or 

experience to use the device or whose physical, 

sensory or intellectual capacities are limited 

must never be allowed to use the device without 

supervision or instruction by a person responsible 

for their safety.

J     

   Explosion hazard! Protect yourself 

from a highly explosive oxyhydrogen 

gas reaction! Gaseous hydrogen 

 

 can leak from the battery during the charging 

and discharging process. Oxyhydrogen gas is 

an explosive mixture of gaseous hydrogen and 

oxygen. The result is the so-called oxyhydrogen 

reaction upon contact with open fire (flames, 

embers or sparks)! Carry out the charging or 

discharging procedure in a wellventilated room 

protected from the weather. Make sure that there 

are no sources of open fire (flames, embers or 

sparks) in the vicinity when charging or discharg-

ing batteries! 

J     

   Danger of explosion and fire! Make 

sure that explosive and flammable 

substances e.g. petrol or solvents 

 

can be ignited when using the charging station!

m   Danger of chemical burns! Protect your eyes 

and skin against chemical burns caused by acid 

(sulphuric acid) upon contact with the battery! 

Do not look directly at the connected battery.

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Safety

J

 

   Wear protective goggles! 

Wear protective gloves!

 

 If your eyes or skin come into contact with sul-

phuric acid, rinse the affected part of the body 

with plenty of clear running water and seek im-

mediate medical assistance!

J     

   Protect yourself from an electric 

shock! When connecting the charging 

station, use a screwdriver and a 

 

spanner with an insulated handle!

J   

Caution! Risk of injury! Do not use the 

charger to charge dry-cell batteries

J   

On no account should you take the charger apart. 

A charger that has not been properly assembled 

can lead to a life-threatening electrical shock.

J     

 Do not use the charging station for charging or 

trickle-charging a damaged or frozen battery!

J     

 Before connecting to the mains, make sure that 

the mains current is equipped with standard 

230 V ~ 50 Hz, PEN conductor, a 16 A fuse and 

a residual-current circuit-breaker!

J     

 Only touch the pole connecting cables (“–” and 

“+”) in the insulated area!

J     

 Only carry out the assembly, maintenance and 

servicing of the charging station when it is dis-

connected from the power supply!

J     

 Do not position the charging station near a fire or 

subject it to heat or to long-term temperatures 

exceeding 50 °C! The output capacity of your 

charging station is automatically reduces at high 

temperatures.

J

  Do not cover the charger!

J     

 Protect the electrical contacts of the battery 

against short-circuiting!

J     

 Do not place the charging station driectly on or 

next to the battery!

J   

Set the charger up as far away from the battery 

as the charging cable allows.

J   

   Protect yourself from electric 

shock. Never touch both alligator clips 

at the same time when the charger is 

 

operating

J   

Remove the power cable from the socket before 

connecting the charging cable to the battery or 

disconnecting the cable from the battery.

J     

 After completing the charging and floating charge 

operation on a battery permanently installed in 

the vehicle, first disconnect the cable of the 

negative (minus) pole (black) of the charger 

from the negative (minus) pole of the battery.

J   

Always turn your face away from the battery when 

you connect the charging cable to the battery.

J     

 In case of malfunction or damage, immediately 

disconnect the charging station from the mains!

J     

 Have the charging station repaired by authorised 

and trained specialists only! Please contact the 

service department for your country!

J     

 Before connecting the charging station, read 

the information on battery maintenance in the 

operating instructions of the battery!

J     

 Before connecting the charging station to a bat-

tery permanently installed in a vehicle, read the 

information on electrical safety and maintenance 

in the operating instuctions of the vehicle!

J

   Disconnect the charger from the mains current 

and the battery when not in use!

q  

Properties

This device is designed for charging open batteries 

and a variety of closed batteries that are used in cars, 

motorbikes and a few other vehicles - e.g. WET (with 

liquid electrolyte), GEL (with a gel electrolyte) or AGM 

batteries (with electrolyte-absorbing mats). The bat-

tery capacity ranges from 12 V (14 Ah) to 12 V (230 Ah) 

or from 24 V (14 Ah) to 24 V (120 Ah). A special design 

feature of the device permits the battery to be re-

charged to nearly 100% of its capacity. In addition, 

long-term connection of the battery to the charger 

is possible when not in use in order to maintain it in 

its best possible condition without damaging it. The 

charger has a total of 6 charging modes for various 

batteries in various conditions. This enables charg-

ing to be safer and more efficient. In contrast to 

conventional products, the charger has a special 

function that enables nearly completely flat batteries 

to be recharged. The highest protective measures 

against incorrect use and short-circuiting ensure 

safe operation. Thanks to an integrated switch, the 

charger only starts the charging process when the 

charging mode has been selected. This means that 

the spark that often occurs when connecting the 

battery is completely avoided.

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Before starting device up for the first time / Operation

q  

Before starting device up 

for the first time

J   

Clean the battery clips. Make sure that your 

eyes do not come into contact with rust.

J   

Ensure sufficient ventilation. Gaseous hydrogen 

can leak out when charging or trickle charging 

the battery.

q  

Operation

q  

Connection

j   

Connect the connecting cable p or [ to the 

connection adaptor ].

j   

Clamp the “+”-pole (red) y, i of the charger 

to the “+”-pole of the battery.

j   

Clamp the “–”-pole (black) u, o of the 

charger to the “–”-pole of the battery.

 

 Note: Make sure that the “+”-pole y, i or 

the “–”-pole u, o sits firmly. 

j   

Connect the power cable r to the mains current.

As soon as you have connected the battery to the 

charger, the charger automatically switches to 

STANDBY mode. The “POWER” display w glows.

Note: The charger has its own reverse battery 

protection. The LED 

 “Error” Q shines when the 

“+”-pole y, i or “–”- pole u, o has been wrongly 

connected.

q  

Disconnecting

j   

Disconnect the power cable r from the mains 

current.

j   

Remove the “–”-pole (black) u, o of the 

charger from the “–”-pole of the battery.

j   

Remove the “+”-pole (red) y, i of the charger 

from the “+”-pole of the battery.

q  

Select mode of operation

j   

Press the “MODE” button q to select the mode 

of operation you want to have. The LED for the 

mode of operation you want will glow steadily.

You can choose between the following modes 

of operation:

Mode 1   28.8 V (24 V / 3.5 A):

Suitable for batteries with a capacity of more than 

14 Ah in normal conditions. Charging mode for 

open batteries, MF and for most GEL batteries.

-   The LED for Mode 1 } lights up. As soon as 

the integrated switch is thrown, the appropriate 

LED for the state-of-charge also comes on 

(see “State of charge”). The charging process 

starts with an amperage of 3.5 A. As soon as 

the battery has been fully charged (28.8 V) the 

following LEDs light up:   W,   E,   R 

and   T.

 

 The charger changes over to trickle charging.  

If the voltage of the battery falls below 25.6 V, 

the charging process starts up again with an 

amperage of 1.5 A until the battery has been  

fully charged again (28.8 V).

Mode 2 

 29.4 V (24 V / 3.5 A):

Suitable for batteries with a capacity of more than 

14 Ah in cold conditions or also for many AGM  

batteries (with electrolyte-absorbing mats) with a 

capacity of more than 14 Ah.

-   The LED for Mode 2 { lights up. As soon as the 

integrated switch is thrown, the appropriate LED 

for the state-of-charge also comes on (see “State 

of charge”). The charging process starts with an 

amperage of 3.5 A. As soon as the battery has 

been fully charged (29.4 V) the following LEDs 

light up:   W,   E,   R and   T.

 

 The charger changes over to trickle charging.  

If the voltage of the battery falls below 25.6 V, 

the charging process starts up again with an 

amperage of 1.5 A until the battery has been 

fully charged again (28.8 V).

Mode 3   14.4 V (12 V / 7 A):

Suitable for batteries with a capacity of more than 

14 Ah in normal conditions. Charging mode for open 

batteries, MF and for most GEL batteries.

-   The LED for Mode 3 P lights up. As soon as the 

integrated switch is thrown, the appropriate LED 

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Operation

for the state-of-charge also comes on (see “State 

of charge”). The charging process starts with 

an amperage of 7 A. As soon as the battery has 

been fully charged (14.4 V), the following LEDs 

light up:   W,   E,   R and   T.

 

 The charger changes over to trickle charging.  

If the voltage of the battery falls below 12.8 V, 

the charging process starts up again with an 

amperage of 1.5 A until the battery has been 

fully charged again (14.4 V).

Mode 4 

 14.7 V (12 V / 7 A):

Suitable for batteries with a capacity of more than 

14 Ah in cold conditions or also for many AGM  

batteries (with electrolyte-absorbing mats) with a 

capacity of more than 14 Ah.

-   The LED for Mode 4 O lights up. As soon as the 

integrated switch is thrown, the appropriate LED 

for the state-of-charge also comes on (see “State 

of charge”). The charging process starts with 

an amperage of 7 A. As soon as the battery has 

been fully charged (14.7 V) the following LEDs 

light up:   W,   E,   R and   T.

 

 The charger changes over to trickle charging.  

If the voltage of the battery falls below 12.8 V, 

the charging process starts up again with an 

amperage of 1.5 A until the battery has been 

fully charged again (14.4 V).

q  

Trickle charging (13.6 V / SUPPLY)

Note: In this mode, the charger has overload 

protection (max. 6.0 A).

Note: As soon as the output voltage falls below 4.5 V, 

the charger automatically switches to STANDBY mode.

Caution! There is no reverse battery protection in 

this mode (see “Connecting”)!

Suitable for maintaining the state-of-charge of  

batteries with a capacity of more than 14 Ah in  

normal conditions or for an electrical power supply 

of 13.6 V / 5 A.

12 V SLA batteries (sealed lead-acid batteries):

-    The LED for the maintenance mode I lights 

up. As soon as the integrated switch is thrown, 

the LED for the maintenance mode I flashes. 

The process starts with an amperage of 13.6 A 

(±0.25 V) / 5 A (±10 %).

Using it as a power source:

j   

Press the “MODE” button q down for about 

3 seconds. 

-   The LED for the maintenance mode I lights up. 

As soon as the integrated switch is thrown, the 

LED for the SUPPLY Y lights up. The electrical 

power supply starts with an amperage of 13.6 A 

(±0.25 V) / 5 A (±10 %).

q  

State of charge

The state-of-charge of the connected battery is indicated on the charger as follows:

LED

Display

 W

flashes

steady glow

steady glow

steady glow

steady glow

 E

off

flashes

steady glow

steady glow

steady glow

 R

off

off

flashes

steady glow

steady glow

 T

off

off

off

flashes

steady glow

State-of-charge

- 25%

- 50%

- 75%

- 100%

100%

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Operation / Maintenance

q  

Regeneration mode (16 V BOOST)

Note: This mode is only suitable for 12 V batteries.

Note: In this mode, the batteries have to be charged 

fully!

Suitable for the regeneration of completely flat  

batteries with a capacity of more than 14 Ah in normal 

conditions.

-   The LED for the regeneration mode U lights 

up. As soon as the integrated switch is thrown, 

the LED for the regeneration mode U flashes. 

The process starts with an amperage of 16.5 A 

(±0.25 V) / 1.5 A (±10 %).

 

 Note: If the battery is nearly completely flat, the 

LED for the regeneration mode U could flash for 

up to 3 hours. During this time, constant amper-

age of 1500 mA will flow into the battery in order 

to restore the battery’s capacity. After a maximum 

of 4 hours, the regeneration mode switches itself 

off. If the battery has still not been fully charged, 

the charger will switch to normal charging mode 

(mode 1 - 4).

q  

Impulse charging

As soon as the charger starts the charging process, 

it automatically recognises the battery voltage. It 

changes over to impulse charging when the battery 

voltage is in the area of 4.5 V / 14 V to 10.5 V / 21 V. 

This impulse charging continues until the battery 

voltage rises to more than 10.5 V / 21 V; after that 

the charger changes back to the charging mode 

selected before. This process is able to regenerate 

most flat, used or overcharged batteries so that 

they can be re-used.

q  

Charger protection function

As soon as an abnormal situation such as a short-

circuit, regeneration process of more than 7 hours, 

charging process of more than 41 hours, battery 

voltage less than 4.5 V (with 12-V batteries) or 16 V 

(with 24-V batteries), open electric circuit or reversed 

polarity occurs, the charger switches over to STANDBY 

mode. If you do not input any other setting, the system 

will remain on STANDBY. With reversed polarity, the 

LED 

 “Error” Q will light up. This way, the sparks 

that often arise during the connection process are 

avoided.

q  

Overheating protection

If the appliance becomes too hot during charging, 

the power output is automatically reduced. This 

protects the appliance from damage.

q  

Memory function

Note: The memory function is not active in mainte-

nance and regeneration mode.

The charger has a memory function. As soon as the 

charger has been connected to the mains supply, it 

automatically switches to the mode of operation last 

used. Due to the variety of different batteries and 

conditions, we recommend you check the mode of 

operation carefully and make any manual adjustments 

if necessary (See “Selecting mode of operation”).

q  

Average charging time

Battery type 

(Ah)

For about 80% state-of-charge

(time in hours) 

12 V

24 V

14

2,5

4,9

60

7,5

15

100

12

24

120

15

30

230

29

q  

Maintenance

The appliance is maintenance-free.

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Disposal / Information

q  

Disposal

   The packaging is wholly composed of 

environmentally-friendly materials that 

can be disposed of at a local recycling 

centre.

   Do not dispose of electrical 

appliances in household waste.

q  

Information

q  

Servicing

J     

  Have your device repaired only by quali-

fied specialist personnel using original 

manufacturer parts only. This will ensure 

that your device remains safe to use.

We reserve the right to make technical modifications in 
the course of product development.

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WWW.4LOAD.DE

CHARGE BOX 7.0

Stand der Information: 09/2008

4 Load GmbH

Glendale Str. 4
87700 Memmingen
Germany
www.4load.de

BATTERY-CHARGER 7,0 AMP

USER MANUAL