DEFA 453115 Power Supply 1204R Flex Onboard Charger User Guide

DEFA 453115 Power Supply 1204R Flex Onboard Charger

Product Information:

The PowerSupply 1204R Flex is a permanent installation power supply designed for use in vehicles. It requires installation in accordance with the instructions applicable to the vehicle model. It comes with Termini TM connectors, a 7.5A fuse, and red and black wires that connect to a 12V battery. The power supply is compatible with El/hybrid/optional El/hybride.

Usage Instructions:

1.  Before using the power supply, read all instructions and cautionary markings on the power supply, battery, and product using battery.

2. Install the power supply permanently in the vehicle in
   accordance with the instructions applicable to the vehicle model.

3. Use only attachments recommended or sold by DEFA to avoid risks of fire, electric shock or injury to persons. To disconnect the power supply, pull by plug rather than cord to reduce risk of damage to electric plug and cord.

4. Do not disassemble the power supply. Return it to an authorized DEFA product dealer when service or repair is required. Unplug the power supply from the outlet before attempting any repair or service.

5. Read all battery manufacturer’s specific precautions while charging and recommended rates of charge. Determine the voltage of the battery by referring to the car owner’s manual and make sure that the power supply is appropriate.

6. Locate the power supply as far away from the battery as DC wires permit. Never place the power supply directly above the battery being charged. Never allow battery acid to drip on the power supply when reading electrolyte specific gravity or when filling the battery. Do not operate the power supply in a enclosed area or restrict ventilation in any way. Do not place a battery on top of the power supply.

7. Connect and disconnect DC output terminals only after removing ac cord from electric outlet. Never connect positive post to negative post or vice versa. For a negative-grounded vehicle, connect the POSITIVE (RED) terminal from power supply to the chassis (as in most vehicles). For a positive-grounded vehicle, connect the NEGATIVE (BLACK) terminal from power supply to the chassis (as in most vehicles).

8. To achieve voltage on both engine- and interior heater output, supply a +12V signal to the control inlet signal marked with a clock on the power supply. This is normally supplied via the DEFA control units yellow cable. If a control unit is not mounted, this signal can be achieved using the red cap that comes with the power supply. The relay will only be activated and load voltage when both +12V control signal and 120V is connected to the power supply.

OVERVIEW

Connection diagram

WarmUp Bluetooth with 1204R Flex/ WarmUp Bluetooth avec 1204R Flex

Warmup direct connection with 1204R Flex

1204R Flex without Warmup

IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for the PowerSupply 1204R Flex

2. Before using the power supply, read all instructions and cautionary markings on the power supply, battery, and product using battery. This power supply is designed for permanent installation in the vehicle and must be installed in accordance to the installation instructions applicable to your vehicle model.

3. Use of an attachment not recommended or sold by DEFA may result in a risk of fire, electric shock or injury to persons.

4. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting the power supply.

5. Do not use an extension cord between the DEFA power cord and the 120V AC power outlet.

6. Do not operate the power supply with damaged cord or plug – replace the cord or plug immediately.

7. Do not operate the power supply if it has received a sharp blow, been dropped, or otherwise damaged in any way;return it to an authorized DEFA product dealer.

8. Do not disassemble the power supply ; return it to an authorized DEFA product dealer when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

9. To reduce risk the of electric shock, unplug the power supply from the outlet before attempting any maintenance or cleaning.

10. WARNING – RISK OF EXPLOSIVE GASES.

11. 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 YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE POWER SUPPLY.

12. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in vicinity of battery. Review cautionary marking on these products and on engine.

13. PERSONAL PRECAUTIONS

14. Consider having someone close by to come to your aid when you work near a lead-acid battery.

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

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

17. 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.

18. NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.

19. 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 parts which may cause an explosion.

20. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.

21. ONLY POWER LEAD/ACID, AGM, EFB, GEL, and LITHIUM TYPE BATTERIES. OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE. It is not intended to supply power to a low-voltage electrical system other than in a starter-motor application. Do not use the power supply 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.

22. NEVER power a frozen battery.

23. PREPARING TO CHARGE

24. Make sure all accessories in the vehicle are off, so as not to cause an arc.

25. Be sure the area around the battery is well-ventilated while the battery is being powered.

26. Clean the battery terminals. Be careful to keep corrosion from coming in contact with your eyes.

27. Add distilled water in each cell until 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, carefully follow the manufacturer’s recharging instructions.

28. Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.

29. Determine the voltage of the battery by referring to the car owner’s manual and make sure that the power supply is appropriate

30. POWER SUPPLY LOCATION

31. Locate the power supply as far away from the battery as DC wires permit.

32. Never place the power supply directly above the battery being charged; gases from the battery will corrode and damage the power supply.

33. Never allow battery acid to drip on the power supply when reading electrolyte-specific gravity or when filling the battery.

34. Do not operate the power supply in an enclosed area or restrict ventilation in any way.

35. Do not place a battery on top of the power supply.

36. DC CONNECTION PRECAUTIONS

37. Connect and disconnect DC output terminals only after removing ac cord from electric outlet. Never allow the terminals to touch each other.

38. Attach terminals to the battery and chassis as indicated in 16(e) and (f).

39. FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN THE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

40. Position AC and DC cords to reduce any risk of damage by the hood, door, or moving engine parts.

41. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.

42. Check polarity of battery posts. The POSITIVE (RED, +) battery post usually has larger diameter than the NEGATIVE (BACK,–) post.

43. Determine which post of battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most vehicles), see (e). If the positive post is grounded to the chassis, see (f).
    For a negative-grounded vehicle, connect the POSITIVE (RED) terminal from the power supply to the POSITIVE ungrounded post of the battery. Connect the NEGATIVE (BLACK) terminal to the vehicle chassis or engine block, away from the battery. Do not connect the terminal to the carburetor, fuel lines, or sheet-metal body parts.
    Connect to a heavy gage metal part of the frame or engine block.

44. For positive-grounded vehicles, connect teh NEGATIVE (BLACK) terminal from the power supply to the NEGATIVE ungrounded post of the battery. Connect the POSITIVE (RED) terminal to the vehicle chassis or engine block, away from the battery. Do not connect the terminal to the carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block.

45. When disconnecting the power supply, turn switches to off, disconnect AC cord, remove the terminal from the vehicle chassis, and then remove the terminal from the battery.

46. GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS
    The power supply must be grounded to reduce risk of electric shock. The power supply is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. DANGER – Never alter AC cord or plug provided – if it will not fit the power outlet, have proper outlet installed by a qualified electrician. Improper connection can result in a risk of an electric shock.

47. This power supply is intended for use with a nominal 120-volt circuit, which has a grounding plug that looks like the plug illustrated in Figure A. Do not attempt to use an adapter or extension cord.

INSTALLATION

Connect the power supply in accordance with the wiring diagram. Find a suitable place to install the power supply in a distance from the battery that does not exceed the length of the enclosed 12V charging cable. If the cable is extended or cut, the power supply will provide wrong voltage. If the 12V cable is extended, a cable with a larger cross-section must be used. Connection to the battery must always be made with the enclosed fuse. Use at least two or more holes on the fastening bracket to install the power supply or use the supplied cable ties. Make sure the power supply is not placed too close to hot parts such as an exhaust manifold, turbo and so on. It must also be positioned well clear of moving parts such as pulleys, cooling fans and steering rods.
To achieve voltage on both engine- and interior heater output the control inlet signal (marked with a clock) on the power supply must be supplied with a +12V signal. This is normally supplied via the DEFA control units yellow cable. If a control unit is not mounted, this signal can be achieved using the red cap that comes with the power supply. The relay will only be activated and load voltage when both +12V control signal and 120V is connected to the power supply.

• It is most important that the power supply is installed in accordance with the installation guide and that DEFA´s original connection equipment is used, see specific installation guide.
• Some vehicles have a battery monitoring system. Connect ground according to the vehicle manufacturer’s recommendation.

USE

The power supply has the following characteristics:

• 4A charging output.
• Power distribution and integrated relay for switching engine and interior heater on and off.

The power supply operates independently of the start timer for the car heating system. The power supply can also be used to advantage in the summer. Avoid powering batteries in an enclosed area, as there is a potential danger of explosion. The ambient temperature of the battery should not exceed +40ºC during powering. The power supply contains high voltage. In order to prevent potentially dangerous situations involving faulty batteries, the power supply requires a back voltage of approximately 2V to start operating. It can therefore not be used as a 12V battery eliminator.

TECHNICAL INFORMATION

The PowerSupply is tested and

satisfies the standards:

| UL 1236; CSA C22.2#107.2; FCC Part 15, Subpart B; ICES-003

www.defa.com

References

• DEFA • World leading preheating, charging and inverter systems

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>