Rossi CD-230P User Manual

Full Text Searchable PDF User Manual

ROSSI Chargers

User Manual

WARNING!

Read and understand all

safety warnings and instructions carefully
before using this machine. Failure to
follow the warnings and instructions may
result in electric shock, fire and/or serious
injury. Save this manual for future
reference

ATTENTION!

Products covered by this

manual will vary in appearance, assembly,
inclusions, description and packaging.

NOTE!

This manual covers multiple

styles of product as well as options /
accessories that may not be suitable for
the machine you have purchased.

Product Manual

– Battery Charger / Starter

Index

Index ............................................................................................................................................................. 1

Safety ........................................................................................................................................................... 2

Parts Diagrams ............................................................................................................................................. 5

Assembly (CD-230P, CD-280P & CD-430P models) .................................................................................... 7

Using your Charger ....................................................................................................................................... 8

Charging Mode output (1, 2 & BOOST, MIN options) ................................................................................................... 8

Charging ........................................................................................................................................................................ 8

Battery is installed in a vehicle ...................................................................................................................................... 9

Battery removed / away from vehicle .......................................................................................................................... 10

Using the Engine “Jump Start” feature ........................................................................................................................ 10

General Charging Notes .............................................................................................................................................. 11

Calculating charge time (guide only) ........................................................................................................................... 11

Maintenance ............................................................................................................................................... 11

Fuses ........................................................................................................................................................................... 12

Transporting & Storage ............................................................................................................................... 13

Troubleshooting .......................................................................................................................................... 13

Specifications ............................................................................................................................................. 16

Appendix .................................................................................................................................................... 17

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Safety

t is important you read

and understand the
instruction manual before
use and keep the manual
in a safe place for future
reference.

Safety precautions must
be observed to reduce the
risk of personal injury
when operating this
machine

It is strongly
recommended that a
comprehensive training
course on machine use,
handling and operation be
completed before
attempting to use this
machine.

IMPORTANT! Like all power
equipment this unit must be
handled carefully.

DANGER! Electric Shock can
kill.

DANGER! Exposure to fumes
and gases can damage the
lungs and respiratory system
or cause asphyxiation.

WARNING! Risk of electric
shock or fire.

To reduce the risk of damage to the
electric plug or cord, pull by the plug
rather

than

the

cord

when

disconnecting

the

charger.

extension  cord  should  not  be  used
unless  absolutely  necessary.  Use  of
an  improper  extension  cord  could
result  in  a  risk  of  fire  and  electric
shock.  If  an  extension  cord  must  be
used, make sure:
a.  That  the  pins  on  the  plug  of  the

extension cord are the same
number, size and shape as those
of the plug on the charger.

b. That the

extension

cord

properly wired and in good
electrical condition.

c. That the wire size is large enough

for the AC ampere rating of the
charger.

Do  not  operate  the  charger  with  a
damaged  cord  or  plug;  have  the  cord
or  plug  replaced  immediately  by  a
qualified  service  person.  Do  not
operate  the  charger  if  it  has  received
a  sharp  blow,  been  dropped  or
otherwise damaged in any way; take it
to  a  qualified  service  person.  Do  not
disassemble  the  charger;  take  it  to  a
qualified service person  when service
when  repair  is  required.  Incorrect
reassembly may result in a risk of fire
or electric shock.

WARNING! Risk of explosive
gases. Working in the vicinity
of a battery is dangerous.
Batteries generate explosive
gases during normal battery
operation. For this reason, it is
of utmost importance that you
follow the instructions each
time you use the charger.

To  reduce  the  risk  of  a  battery
explosion,  follow  these  instructions
and  those  published  by  the  battery
manufacturer and the manufacturer of
any  equipment  you  intend  to  use  in
the  vicinity  of  the  battery.  Review  the

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cautionary

markings

these

products and on the charger.

WARNING!  Do  not  use  with  non-
rechargeable  batteries.  Use  only
with  lead-acid  type  rechargeable
batteries.

PERSONAL SAFETY

Stay  alert,  watch  what  you  are  doing
and  use  common  sense  when
operating  equipment.  Do  not  use
equipment  while  you  are  tired  or
under  the  influence  of  drugs,  alcohol
or

medication.

moment

inattention  while  operating  equipment
may  result  in  serious  personal  injury.
Use  personal  protective  equipment.
Always

wear

eye

protection.

Protective  equipment  such  as  dust
mask,  non-skid  safety  shoes,  hard
hat,  or  hearing  protection  used  for
appropriate  conditions  will  reduce
personal

injuries.

Ensure

the

equipment  is  switched  off  before
connecting  to  power  source,  picking
up  or  carrying  the  equipment.  Never
carry  equipment  with  your  finger  on
the switches.

WARNING! Risk of explosive
gases

Remove personal metal items such as
rings,

bracelets,

necklaces

and

watches  when  working  with  a  lead-
acid  battery.  Batteries  can  produce  a
short  circuit  current  high  enough  to
weld  a  ring  or  the  like  to  metal,
causing  a  severe  burn.  Be  extra
cautious,  to  reduce  the  risk  of
dropping a metal tool onto the battery.
It  might  spark  or  short-circuit  the
battery  or  other  electrical  part  that
may  cause  an  explosion.    Use  this
charger  for  charging  12V  or  24V
LEAD-ACID

batteries

only,

only

charge  a  battery  with  the  same
voltage  as  the  charger  is  set  to.  It  is
not intended to supply power to a low
voltage  electrical  system.  Do  not  use
this  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.

WARNING! NEVER charge a
frozen battery OR overcharge a
battery.

Consider  having  someone  nearby  to
come to your aid when you work near
a  battery.  Have  plenty  of  fresh  water
and  soap  nearby  in  case  battery  acid
contacts your skin, clothing or eyes. If
battery  acid  contacts  your  skin  or
clothing,  immediately  wash  the  area
with  soap  and  water.  If  acid  enters
your  eye,  immediately  flood  the  eye
with cold running water for at least 10
minutes  and  get  medical  attention
right

away.

battery

acid

accidentally swallowed, drink milk, the
whites of eggs or water. DO NOT
induce

vomiting.

Seek

medical

attention immediately.

PREPARING TO CHARGE

WARNING! Risk of contact with
battery acid. Battery acid is a
highly corrosive sulfuric acid.

Remove all cord wraps and uncoil the
cables  prior  to  using  the  battery
charger.  If  it  is  necessary  to  remove
the battery from the vehicle to charge
it,  always  remove  the  grounded
terminal  first.  Make  sure  all  of  the
accessories  in  the  vehicle  are  off  to
prevent  arcing.  Clean  the  battery
terminals  before  charging  the  battery.
During

cleaning,

keep

airborne

corrosion  from  coming  into  contact
with  your eyes, nose and  mouth. Use
baking  soda  and  water  to  neutralize
the  battery  acid  and  help  eliminate
airborne  corrosion.  Do  not touch  your
eyes,  nose  or  mouth.  Add  distilled
water  to  each  cell  until  the  battery
acid reaches the level specified by the
battery  manufacturer.  Do  not  overfill.
For  a  battery  without  removable  cell
caps,  such  as  valve  regulated  lead
acid batteries (VRLA), carefully follow
the

manufacturer’s

recharging

instructions. Read, understand and
follow all instructions for the charger,

battery,  vehicle  and  any  equipment
used  near  the  battery  and  charger.
Study  the  battery  manufacturer’s
specific  precautions  while  charging
and  recommended  rates  of  charge.
Make sure that the charger cable clips
make tight connections.

CHARGER LOCATION

WARNING! Risk of explosion
and contact with battery acid.

Locate  the  charger  as  far  away  from
the  battery  as  the  DC  cables  permit.
Never  place  the  charger  directly
above  the  battery  being  charged;
gases  from  the  battery  will  corrode
and  damage  the  charger.  Do  not  set
the  battery  on  top  of  the  charger.
Never  allow  battery  acid  to  drip  onto
the

charger

when

reading

the

electrolyte specific gravity or filling the
battery.

ELECTRICAL SAFETY

WARNING! Risk of electric
shock or fire.

Equipment  plugs  must  match  the
outlet.  Never  modify  the  plug  in  any
way.  Do  not  use  any  adapter  plugs
with  earthed  (grounded)  equipment.
Touching  live  electrical  parts  can
cause fatal shocks or severe burns.
This  battery  charger  is  for  use  on  a
nominal 240V, 50 Hz circuit. The plug
must be plugged  into an outlet that is
properly  installed  and  grounded.  The
plug  pins  must  fit  the  receptacle
(outlet).

not

use

with

ungrounded system.

DANGER! Never alter the power
cord or plug provided

– if it

does not fit the outlet, have a
proper

grounded

outlet

installed

qualified

electrician.

improper

connection can result in a risk
of

electric

shock

electrocution.

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Parts Diagrams

ATTENTION! Products covered by this manual will vary in appearance, assembly, inclusions, description
and packaging.

1.  100 Amp fuse
2.  Ammeter
3.  1 / 2 switch
4.  MIN / BOOST switch
5.  Charge  / Jump Start switch
6.  Power On/Off
7.  24V terminal
8.  Terminal swap cable
9.  12V terminal
10.  Terminal CAP
11.  Negative (Ground) clamp
12.  Positive clamp

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1.  Ammeter
2.  30A Fuse
3.  12V / 24V mode switch
4.  Overheat Fuse
5.  MIN / BOOST switch
6.  Cable Caddy
7.  Power On/Off switch
8.  Rear panel

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Assembly (CD-230P, CD-280P & CD-430P models)

Note! The GZL-30P does not require any assembly.

1. Lay the charger down on a flat stable surface so you can access the undercarriage.
2. Slide the steel

“axle shaft” into the axle holder on the bottom of the charger leaving some of the

shaft protruding (around 50mm).

Slide on one “wheel” followed by one “steel washer”.

Slide one “C-Clip” into the circular groove around the end of the “axle shaft” until it snaps into place
securely.

Push on the “plastic wheel cap” over the end of the “axle shaft” until it snaps in place. The “wheel”
should lock on to the “C-Clip” installed in step 4.

6. Repeat steps 3

to 5 for the opposite side of the “axle shaft”.

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Using your Charger

WARNING! Monitor the charging progress and stop it when the battery is charged. Not doing so may
cause damage to your battery or may cause other personal property damage or personal injury.

1. 1 (min charge and 2 (max charge) under

“Trickle charge mode”

(disabled if Boost is selected)

Low “trickle charge” mode.

High “trickle charge” mode.

2. Boost (full power) / Min (trickle charge)

Trickle charge mode

Boost Charge mode

3. Mode Select

Battery Charge

Jump Start

4. On / Off Switch

NOTE! Some batteries can be very sensitive and damaged if charged with too high an input; consult your battery
manufacturer for support.

Ammeter

The Ammeter indicates the amount of current, measured in amps, that is being drawn by the
battery. As a battery takes on a charge, it draws less current from the charger. Correspondingly,
the meter will show less current being drawn by the battery. When the current stops decreasing,
the battery is charged.

Charging Mode output (1, 2 & BOOST, MIN options)

BT280P (CD230P)



MIN with Button (1) - Charging Current: 26Amp=26000mA; 0.65KW



MIN with Button (2) - Charging Current: 31Amp=31000mA; 0.80KW



BOOST with Button (1) - Charging Current: 33Amp=33000mA; 1.0KW



BOOST with Button (2) - Charging Current: 36Amp=36000mA; 1.30KW

BT750P (CD430P)



MIN with Button (1) - Charging Current: 31Amp=31000mA; 0.80KW



MIN with Button (2) - Charging Current: 36Amp=36000mA; 1.30KW



BOOST with Button (1) - Charging Current: 3Amp=43000mA; 1.6KW



BOOST with Button (2)- Charging Current: 50Amp=50000mA;2.0KW

Charging

NOTE! Check that it is a 12 volt or 24 volt battery you are charging.

1. Place the charge rate to the preferred position (12V or 24V)
2. Ensure that all of the charger components are in place and in good working condition, including the plastic

boots on the battery clips. Make sure the electrolyte (battery liquid) in each cell is at the correct level.

3. Set the mode to Battery Charge and boost to the desired setting (MIN or BOOST)

a. GZL-30P; simply press the switch to select.
b.

All other models; unscrew the “Terminal cap”, move the Terminal swap cable unto the appropriately
marked 12V or 24V terminal.

4.  Set the Charge function to the desired setting (1- Low / 2- High).
5.  Connect the battery following the precautions listed in this manual.
6.  Connect the AC power following the precautions listed in this manual.
7.  To disconnect the charger, reverse the procedure.

12V / 24V Charge Rate.

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You may select the output voltages of 12 or 24 volts for charging the batteries of those voltages or battery
combinations connected in series (not parallel) in which the sum of the battery voltages adds up to the range selected.

IMPORTANT! Consult an alternative power expert before using this charger to charge multi battery
installations.

WARNING! This is a manual battery charger. Charging must be monitored often to prevent overcharging
of the battery. Overcharging a battery could cause personal injury and/or property damage.

Battery is installed in a vehicle

IMPORTANT!

To reduce the risk

of a spark near the battery,
position the ac and dc cables to
reduce the risk of damage by the
hood, door and moving or hot
engine parts.

IMPORTANT!

Check the polarity

of the battery posts. The positive
(POS, p, +) battery post
sometimes have a larger diameter
than the negative (NEG, n, -) post.
Determine which post of the
battery is grounded (connected)
to the chassis.

NOTE!

Always leave the bonnet

open during charging to ensure
the bonnet does not touch the
metal part of the battery clips.
Stay clear of fan blades, belts,
pulleys and other parts that can
cause injury.

WARNING!

Do not connect the

clip to the carburettor, fuel lines or
sheet-metal body parts.

WARNING!

A spark near the

battery may cause a battery
explosion.

WARNING!

Make sure that the

vehicles are not touching each
other and that the jumper lead
clamps do not touch each other.

NEVER!

Remove the Clamps

while an engine is running, there
is a risk of damaging delicate
computers in a vehicle as well as
risk of battery explosion.

Before proceeding ensure that the ignition of both vehicles and anything that could cause an electrical
load i.e. headlights, interior light etc., are turned off, and keys are removed from the ignition of both
vehicles.

Before charging or jump starting always consult the vehicle manufacturer or your Vehicles manual for
more advice and techniques on how to jump start your vehicle to reduce and risk to electrical equipment /
computers.

For a negative-grounded vehicle:

a. Connect the POSITIVE (RED) clip from the battery charger to the POSITIVE (POS, P, +) ungrounded post of

the battery.

b.  Connect the NEGATIVE (BLACK, NEG, N, -) clip to the vehicle chassis or engine block away from the battery.
c.  Connect to a heavy gauge metal part of the frame or engine block.
d.  Connect charger AC supply cord to electrical outlet. When disconnecting the charger, disconnect the AC cord,

remove the clip from the vehicle chassis and then remove the clip from the battery terminal.

For a positive-grounded vehicle:

a. Connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, -) ungrounded

post of the battery.

b.  Connect the POSITIVE (RED) clip to the vehicle chassis or engine block away from the battery.
c.  Connect to a heavy gauge metal part of the frame or engine block.
d.  Connect  charger  AC  supply  cord  to  electrical  outlet.  When  disconnecting  the  charger,  disconnect  the  AC

cord, remove the clip from the vehicle chassis and then remove the clip from the battery terminal.

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NOTE! See section

“Calculating charge time” for length of charge information.

Battery removed / away from vehicle

WARNING! A spark near the battery may cause a battery explosion.

WARNING! Do not face the battery when making the final connection.

TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post often has a larger diameter
than the NEGATIVE (NEG, N, -) post.

Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) post of the battery.

Position yourself and the free end of the cable you previously attached to the NEGATIVE (NEG, N, -) battery
post as far away from the battery as possible

– then connect the NEGATIVE (BLACK) charger clip to the free

end of the cable.

Connect charger AC supply cord to electrical outlet. When disconnecting the charger, always do so in the
reverse order of the connecting procedure and break the first connection while as far away from the battery as
practical. A marine (boat) battery must be removed and charged on shore.

Using the Engine “Jump Start” feature

CD-230P, CD-280P & CD-430P models only.

Your battery charger can be used to jumpstart your car if the battery is low. Follow these instructions on how to use
the ENGINE START feature.

Before charging or jump starting always consult the vehicle manufacturer or your Vehicles
manual for more advice and techniques on how to jump start your vehicle to reduce and risk to
electrical equipment / computers.

WARNING!

Follow all safety

instructions and precautions for
charging your battery. Wear
complete eye protection and
clothing protection. Charge your
battery in a well-ventilated area.

IMPORTANT!

Using the

ENGINE START feature

WITHOUT a battery installed in
the vehicle could cause damage
to the vehicle’s electrical
system.

NOTE!

If you have charged the

battery and it still will not start
your car, do not use the engine

start feature, or it could

damage

the vehicle’s electrical system.

IMPORTANT!

Do not leave the

charger in ENGINE START
Mode for more than ten minutes
at a time; this may damage the
charger.

1. With the charger unplugged from the AC outlet, connect the charger to the battery, following the instructions

given in previous section

“Battery is installed in a vehicle”.

2. Plug the charger AC power cord into the AC outlet.
3. With the charger plugged in and connected to the battery of the vehicle, set the mode selector switch to the

“jump start” position.

4. Crank the engine until it starts or 3 seconds pass. If the engine does not start, set the jump stater to charge

mode and wait 15min minutes before trying again.

NOTE! During extremely cold weather, or if the battery is under 2 volts, charge the battery for 15 minutes
before cranking the engine.

IMPORTANT! Never charge frozen batteries.

NOTE! When starting a diesel motor; allow the glow plugs to warm up prior to cranking the engine.

5. If the engine fails to start, charge the battery for 10 more minutes before attempting to crank the engine again.
6. After the engine starts, move the charge mode selector switch to the OFF position and unplug the AC power

cord before disconnecting the battery clips from the vehicle.

7. Clean and store the charger in a dry location.

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NOTE: If the engine does turn over but never starts, there is not a problem with the starting system; there
is a problem somewhere else with the vehicle. STOP cranking the engine until the other problem has been
diagnosed and corrected.

General Charging Notes

Cooling Fans:

The charger is designed to control its cooling fan for efficient operation. Keep the area near the

charger clear of obstructions to allow the fan to operate efficiently.

Calculating charge time (guide only)

Use the following table to more accurately determine the time it will take to bring a battery to full charge. First, identify
where your battery fits into the chart. NR means that the charger setting is NOT RECOMMENDED. Find your battery’s
rating on the chart, and note the charge time given for each charger setting. The times given are for batteries with a
50% charge prior to recharging. Add more time for severely discharged batteries.

Maintenance

After use and before performing maintenance, unplug and disconnect the battery charger.

Use a dry cloth to wipe all battery corrosion and other dirt or oil from the battery clips, cords and the charger
case.

Ensure that all of the charger components are in place and in good working condition, for example, the plastic
boots on the battery clips.

Servicing does not require opening the unit, as there are no user-serviceable parts.

All other servicing should be performed by qualified service personnel.

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Fuses

CD-230P, CD-280P & CD-430P models

100 Amp Fuse

– Replace the fuse with

of the supplied

50Amp

blades or use 2 strands of 50Amp fuse wire

(doubled) to make 100Amp.

GZL30P models

30 Amp Blade Fuse

(Output)

5 Amp, 250V glass fuse (F5AL250V)

(Input)

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Transporting & Storage

Store the charger unplugged, in an upright position. The cord will still conduct electricity until it is unplugged
from the outlet.

If the charger is moved around the shop or transported to another location, take care to avoid/prevent damage
to the cords, clips and charger. Failure to do so could result in personal injury or property damage. Store the
clips on the fiberglass clamp rod. Do not store them on the handle, clipped together, on or around metal, or
clipped to the cables.

Troubleshooting

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Specifications

GZL30P - SINGLE PHASE 12V/24V BATTERY CHARGER

Manufacturer: ROSSI
Jump Start feature: No
Input Voltage: 220-240V 50Hz
Charger type: Manual
Charge Voltage: 12V/24V
Rated Charging Power: 1kW
Rated Output Current: 30A
Battery Capacity: 60-200Ah
Fuse: 30A

CD-230P - SINGLE PHASE 12V/24V 280A BATTERY CHARGER

Manufacturer: ROSSI
Jump Start feature: Yes
Input Voltage: 220-240V 50Hz
Charger type: Manual
Charge Voltage: 12V/24V
Rated Charging Power: 1kW
Rated Starting Power: 6.4kW
Start Power 12V/24V: 180A
Rated Charging Current: 30A (12V), 40A (24V)
Fuse: 100A

CD-280P - SINGLE PHASE 12V/24V 280A BATTERY CHARGER

Manufacturer: ROSSI
Jump Start feature: Yes
Input Voltage: 220-240V 50Hz
Charger type: Manual
Charge Voltage: 12V/24V
Rated Charging Power: 1kW
Rated Starting Power: 6.4kW
Start Power 12V/24V: 280A
Rated Charging Current: 30A (12V), 40A (24V)
Fuse: 100A

CD-430P - SINGLE PHASE 12V/24V 280A BATTERY CHARGER

Manufacturer: ROSSI
Jump Start feature: Yes
Input Voltage: 220-240V 50Hz
Charger type: Manual
Charge Voltage: 12V/24V
Rated Charging Power: 1.6kW
Rated Starting Power: 10kW
Start Power 12V/24V: 430A
Rated Charging Current: 50A (12V), 60A (24V)
Fuse: 100A

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Appendix

PDF User Manual

CD-280P CD-430P

Full Text Searchable PDF User Manual