GYS NEOSTART 620 Lead-Acid Battery Charger Instruction Manual

Lead-Acid Battery Charger
Instruction Manual

NEOSTART 320
NEOSTART 420
NEOSTART 620
9-14 / 46-48

SAFETY INSTRUCTIONS

This manual includes guidelines on the operation of your device and the precautions to follow for your own safety. Ensure it is read carefully before first use and keep it handy for future reference. These instructions should be read and understood before anyone operates the product. Any modifications or maintenance that are not specified in the manual should not be undertaken. The manufacturer is not liable for any injury or damage due to non-compliance with the instruction manual. In case of problems or uncertainties, please consult a qualified person that is able to handle the device correctly. This device should only be used for charging and starting within the limits indicated on the device and in the manual. The safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held responsible.
Device is suitable for indoor use only. Do not expose to rain or excessive moisture.
This device may be used by children from age 8 and by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge, provided that they are under supervision or have been told how to use the device safely and are aware of the potential risks. Children must not use the device as a plaything. Cleaning and servicing tasks may not be carried out by children unless they are supervised.
Do not use for charging non-rechargeable batteries
Do not operate the device with a damaged power supply cord or a damaged mains plug.
Never charge a frozen or damaged battery.
Do not cover the device
Do not place the device near a fire or subject it to heat or to long-term temperatures exceeding 50°C
Do not obstruct the cooling vents. Refer to the installation section before operating the machine.
Risk of explosion and fire!
A battery being charged can emit explosive gas.

• During the charge, the battery must be placed in a well-ventilated area.

• Avoid flames and sparks. Do not smoke.

• Protect the electrical contacts of the battery against short-circuiting.
  Acid projection hazard!

• Wear safety goggles and protective gloves

If your eyes or skin come into contact with battery acid, rinse the affected part of the body with plenty of water and seek immediate medical assistance.

Connection / disconnection:

• Disconnect the power supply before connecting/disconnecting the device to/from the battery
• The terminal of the battery that is not connected to the car frame must be connected first. The other connection must be made on the car frame, far from the battery and the fuel line. The battery charger must be connected to the power supply network.
• After the charging process, disconnect the battery charger from the power supply network and remove the connector from the car frame, and then the connector from the battery, in this order.

Connection:

• This device must be connected to an earthed power supply.
• This machine is fuse-protected.
• This equipment is intended for industrial environments (class A) and not for residential sites where the electric current is supplied by the public low-voltage power supply network. There may be potential difficulties in ensuring electromagnetic compatibility on these sites, because of the conducted interferences, as well as radiated radio electrical frequency.
  This hardware is compliant with the IEC 61000-3-12.
  This equipment complies with the IEC 61000-3-11.

Maintenance:

• If the power supply cable is damaged, it must be replaced by the manufacturer, its service agent or an equally qualified person.

• Service should be performed by a qualified person.

• **** Warning! Always remove the power plug from the wall socket before carrying out any work on the device.

• Regularly take off the cover and remove dust with an air gun.
  Take the opportunity to have a qualified person check the electrical connections with an insulated tool.

• Under no circumstances should solvents or other aggressive cleaning agents be used.

• Clean the device’s surfaces with a soft, dry cloth.

Regulations :

• The device complies with European Directive.

• The certificate of compliance is available on our website.

• EAC conformity mark (Eurasian Economic Commission)

• Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).

• Equipment in conformity with Moroccan standards. The declaration C  (CMIM) of conformity is available on our website (see cover page).
  Disposal:

• This product should be disposed of at an appropriate recycling facility. Do not dispose of in the domestic waste.

GENERAL DESCRIPTION

The NEWSTART range is designed to charge and start lead-acid batteries, 12V (6 elements) and 24V (12 elements) :

| Recharge| Starting
---|---|---
Neostart 320| 40 – 400 Ah| 35 – 120 Ah
Neostart 420| 25 – 600 Ah| 35 – 160 Ah
Neostart 620| 45 – 900 Ah| 45 – 200 Ah

Assembling the handle and the wheels (only for the NEOSTART 420 et 620 ) :

POWER SUPPLY

Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed by the machine. The device must be positioned so that the socket is always accessible.
The machine must be connected to a single phase socket (230 V) WITH earth protected by a 16A circuit breaker.

CONNECTION AND DISCONNECTION

IMPORTANT! Before any connection to a vehicle battery, make sure that the booster isn’t connected to the mains and that the booster’s switch is set to OFF (if applicable).
Also, check the battery polarity.
Warning: the cables must not be kinked or in contact with hot or sharp surfaces.

• Disconnect any electronic system from the battery during the charge (do not charge the battery when it’s connected to the vehicle).

Start and charge a battery in-situ :
In the event that the negative terminal is plugged to the car’s chassis :

• Connect the red clamp to the battery’s positive + terminal.
• Connect the black clamp to the vehicle’s chassis, and make sure it is a safe distance from the battery and the fuel/exhaust pipe.
• Connect the device to the mains.
• After use, set the switch to OFF, disconnect the charger from the mains then remove the black clamp, followed by the red clamp. Some vehicles have the positive terminal connected to the chassis, in that case :
• Connect the black clamp to the battery’s negative – terminal.
• Connect the red clamp to the vehicle’s chassis, and make sure it is a safe distance from the battery and the fuel/exhaust pipe (any combustible piping).
• Connect the device to the mains.
• After use, set the switch to OFF, disconnect the charger from the mains then remove the red clamp, followed by the black clamp.

Charging a battery when disconnected from the vehicle :

• Connect the red clamp to the battery’s positive terminal and the black clamp to the battery’s negative terminal.
• After use, set the switch to OFF, disconnect the charger from the mains then remove the red clamp, followed by the black clamp.

USE IN CHARGING MODE

Preliminary precautions

• Choose a sheltered and well-ventilated area or a dedicated battery charging area.
• Remove the battery caps (if applicable) and make sure that the liquid level (electrolyte) is sufficient. If not, add demineralized water and carefully clean the battery lugs and terminals.
• Check that the battery capacity (Ampere hour Ah) and the voltage (Volt V) are compatible with your charger.
• We recommend disconnecting the whole electronic system battery while charging (do not charge the battery when connected to the vehicle). Risk of vehicle electronics damage.

Charge monitoring and state of charge
WARNING: These are traditional chargers. The battery charge will require monitoring and the charge will stop when the operator will set the switch to «OFF» or disconnect the charger from the mains Once the battery is charged, the liquid (electrolyte) contained in the battery will boil. When this starts, it is recommended to stop the charge to prevent any damage to the battery.
Moreover, if the battery is connected to the vehicle (in situ), a prolonged unmonitored charge may damage the vehicle’s onboard electronics. A sulfated battery that cannot be charged can potentially lead to damage to the onboard electronics, as soon as the connection starts.
The end of the charge is when the ammeter’s pin is indicated a value between 0 and 10 A, or by a charge time of 10 h.

Sealed battery
For a sealed battery, it is necessary to be extra careful. The charge must be performed while constantly monitoring the voltage at the battery terminals. It is recommended to stop the charge when the voltage reaches 14.4 V for a 12 V battery and 28.8 V for a 24 V battery. This voltage can be measured with a voltmeter.

Charge
Once the charger is connected to the vehicle battery while following the instructions (see connections and disconnections),
For the NEOSTART 320 :
– Set the switch to CHARGE or BOOST 1 with regards to the battery capacity..
Warning: In Boost 1 mode, the thermal protection may activate if the battery is deeply discharged.

| CHARGE (12-24V)| BOOST 1 (12-24V)
---|---|---
Neostart 320| 40 – 160 Ah (11A)| 90 – 400 Ah (27A)

For the NEOSTART 420 and 620 :
– Set the switch to CHARGE 1 or CHARGE 2 with regards to the battery capacity.

| CHARGE 1 (12-24V)| CHARGE 2 (12-24V)
---|---|---
Neostart 420| 25 – 90 Ah (6A)| 90 – 300 Ah (20A)
Neostart 620| 45 – 140 Ah (10A)| 140 – 450 Ah (30A)

After usage, follow the recommended disconnection procedure.

Charging several batteries simultaneously.
It is possible to charge several batteries simultaneously by connecting them in parallel. The positive terminals are connected to the red clamp and the negative terminals are connected to the black clamp. These batteries or battery groups must be of the same voltage, 12V or 24V.
Charging batteries in series is not recommended.

USE IN STARTER MODE
Preliminary precautions

• Do not disconnect the battery from the vehicle. Connecting the battery can lead to the vehicle’s memory loss and a potential impossibility to restart it.

Start
Once the charger is connected to the vehicle battery while following the instructions (see connections and disconnections), it may be necessary to perform a pre charge in order to start the vehicle.
To perform a precharge, set the switch to «BOOST 2» for the NEOSTART 320 and «BOOST» for the NEOSTART 420 and 620.

NEOSTART  320:

| | Instantaneous| 5 min pre-charge
---|---|---|---
Neostart| 12 V| 35 – 60 Ah| 60 – 120 Ah
320| 24 V| 35 – 45 Ah| 45 – 90 Ah

NEOSTART 420 and 620 :

| Instantaneously| 5 min pre-charge
---|---|---
Neostart 420| 35 – 80 Ah| 80 – 160 Ah
Neostart 620| 45 – 100 Ah| 100 – 200 Ah

To start the vehicle, set the switch to «START». Reach the vehicle controls. By turning the key, the start mode activates. This mode must be stopped once the vehicle is started. It is recommended to do this with 2 people so that the person close to the NEWSTART can switch to START at the exact moment and stop the device once the vehicle has started.
If your engine does not start, wait 2 minutes between each start attempt. The attempt must last 3 seconds at most.
Nb: If the vehicle does not start, it may be a problem other than a faulty battery e.g. alternator, glowplug…
After the use, follow the disconnection procedure.

PROTECTIONS

These clamps have been designed for maximum protection :

• The charging clamps are fully insulated.

• A fuse guarantees protection against polarity inversion and short circuits.
  – Neostart 420 and 620: ref. 054547, calibre 200 A (type SIBA V-Fuse / open type)
  – Neostart 320: ref. 054639, calibre 150 A (type Littlefuse BF1 / 32 V)
  Replacing it requires manual intervention..

• A breaker, on the front panel, guarantees protection against transformer overloads and start attempts in charge mode.
  If the breaker trips, it needs to be manually activated.

• The thermal protection is monitored by a thermostat (cooling for approximately 1/4h). The green indicator switches off in the even of overheating.

SULFATED OR DAMAGED BATTERIES

The NEWSTART does not detect sulfated or damaged batteries.

• The battery is badly damaged when in charge, the ammeter pin goes up quickly to very high intensities. The battery is
permanently damaged.
• In the event of a sulfated battery: set the device to «BOOST» for the Neostart 420 and 620 or «BOOST 2» for the Neostart 320 ad regularly check that the amperemeter indicates a charging current. As soon as the charging current rises, set a charge that matches the battery capacity. If there is no improvement after 5 hours, the battery is permanently damaged.
Warning – This must be done with the battery disconnected from the vehicle!

TROUBLESHOOTING

mains power supply.
Check that the device is on charge mode.
Clamps in short circuits or polarity reversal.| Check that the fuses have not melted and that the circuit breaker is not tripped
The battery that you are trying to charge is faulty.| Check the terminals’ voltage with a voltmeter. If this voltage jumps instantaneously to 2.5V per element, the battery may be sulfated or damaged.
Voltage error (12 -24V)| Check that the switch is on the right setting (12 or 24V)
Following intensive use, your device has entered thermal protection mode.| Wait for 1/4h so the device can cool down.
The charger is properly connected
but it does not charge the battery| Blown fuse| Replace the fuse by a new one.
Bad clamp connections.| Clean the terminals and the clamps. Check the state of the cables and clamps.
Wrong charge settings| Check that the selected voltage matches the battery voltage.
Following intensive use, your device has entered thermal protection mode.| Wait for 1/4h so the device can cool down.
The meter’s pin goes above the maximum marking while the device is set to minimum intensity.| The battery is deeply discharged.| Keep charging using the minimum setting.
Voltage ge error (12 -24V)| Check that the switch is on the right setting (12 or 24V)
Your battery has elements in a short circuit.| Damaged battery Replace the battery.
The fuse blows every time it is replaced| Polarity reversal| Connect the + damp to the battery’s (+) and the + damp to the battery’s (-).
Wrong charge settings| Check that the selected voltage matches the battery voltage.
Current overconsumption on the battery| Do not draw any of the battery’s current during the charge
The machine is charging a 12V battery in 24V mode| Set the switch to 12V.
The fuse trips.| Starts are attempted while the device is in charge mode.| Make sure to set the switch to a start * to prevent damage to the machine. Reset the circuit breaker.
You are charging a 12V battery in 24V mode| Set the switch to 12V.
After charging for a whole day, the end-of-charge indicator does not switch on.| The battery is damaged| Change the battery.
The machine is charging a 24V battery in 12V mode| Set the switch to 24V.

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labor).
The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping off equipment, disassembling).
• Environment-related failures (pollution, rust, dust).
  In case of failure, return the unit to your distributor together with:
  – The proof of purchase (receipt etc …)
  – A description of the fault reported

CIRCUIT DIAGRAM

COMPONENTS

| NEOSTART 320| NEOSTART 420| NEOSTART 620
---|---|---|---
/ DIN socket| 53302
Liting handle support| 71515| 56040
Handle| | 53312
Anmeter| 53318
 Indicator (without green cap)| 51020|
Black clamp| 53786
 Red clamp| 53779
Fuse holder| 56078| 51400
Fuses 150A| 054639 (X2)|
2 Fuses 200A| | 054547 (X2)
Switch| 53301| 53301
Breaker| 52343|
Axle brake| | 71380
---|---|---
  Wheel with cover| 71370
 Positioning support| 56039
Wheel support| 53313
 Breaker 10A (Neostart 420)| 52343
Breaker 10A (Neostart 620)| 52342
Back cover + sticker 420| 53297 + 53299
Back cover + sticker 620| 53297 + 53300
Front panel| 53465

CONTROL PANEL

SYMBOLS

| The recyclable product that falls within waste sorting recommendations (according to Decree n° 2014-1577).
---|---
**IP 21**| Protected against rain and against finger access to dangerous parts.

SAS GUYS
1, rue de la Croix des Landes
CS 54159
53941 SAINT-BERTHEVIN Cedex

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