KICKASS KACHG1212 12V 12Amp Smart Battery Charger 8 Stage Automatic Instruction Manual

8-STAGE AUTOMATIC
BATTERY CHARGER
MCU CONTROLLED – HIGH FREQUENCY S WITCHMODE
MODELS: KACHG1212, KACHG1220
Instruction Manual
Please read user manual carefully before use.

WARNING

• Before using the charger, please read and understand the instructions.
•  Provide adequate ventilation and prevent sparks and flames around the charging area. Explosive gases may escape from the battery during charging.
• Designed For charging 12 Volt Lead Acid, AGM, Gel, and Calcium batteries ONLY.
• Disconnect the 240V AC mains supply before making or breaking the connections to the battery.
• The battery charger must be plugged into an earthed socket-outlet.
• Designed for indoor use only. Do not expose to rain or moisture.
• Connection to the mains supply is to be in accordance with National wiring rules.
• If the AC cord is damaged do not attempt to use the charger. It must be replaced or repaired by a qualified person.
• Do not attempt to charge non-rechargeable batteries.
• Corrosive substances may escape from the battery during charging and damage delicate surfaces. Store and charge in a suitable area.
• Never charge a frozen battery.
• Ensure vehicle engine, ignition, and accessories including lights, appliances, etc are turned off prior to charging.
• This appliance is not intended for use by young children or any person with limited capabilities (mental and physical) unless they have been adequately supervised by a responsible person to ensure that they can use the appliance safely.
• Please store disconnected and out of reach of unsupervised children

FEATURES

8-STAGE AUTOMATIC CHARGING
This is a fully automatic battery charger featuring 8 charging stages
Automatic charging is proven to provide your battery with an optimal charge and maintenance sequence that will also protect your battery from being overcharged.
This allows you to leave the charger connected to the battery indefinitely if required.
8-stage charging is a very a c curate and comprehensive charging process that will result in a better battery performance with a longer life expectancy. This is evident when compared to the use of more traditional chargers.
8-stage chargers are suitable for most battery types including WET, Calcium, Maintenance Free, AGM, and GEL batteries. They may also help restore drained and sulfated batteries.

The 8-Stages Include: Desulphation – Soft Start – Bulk – Absorption – Analyse – Recondition – Float – Maintain

CHARGING PROCESS GENTLY TO NSURE
AN EVEN FLOW ACROSS ACH CELL BEFORE INCREASING THE CHARGE RATE| ALLOWS THE FULL VOLTAGE / CURRENT OUTPUT OF THE HARGER  REQUIRED BY THE BATTERY (DEPENDING ON THE
CHEMISTRY  MODE SELECTED)| AUTOMATICALLY  REDUCES
THE CURRENT OUTPUT WHILST MAINTAINING THE  REQUIRED VOLTAGE (DEPENDING ON THE CHEMISTRY MODE  (SELECTED)
STAGE 5| STAGE 6| STAGE 7| STAGE 8
---|---|---|---
ANALYSIS| RECONDITION| CHARGED| MAINTAIN
THE CHARGER WILL PERFORM A QUICK BATTERY TEST TO ENSURE THE BATTERY CAN HOLD ITS CHARGE|  BOOSTS THE BATTERY BY INCREASING THE VOLTAGE WITH A REDUCED CURRENT OUTPUT TO BRING THE
BATTERY TO ITS FULL STATE| THE BATTERY IS FULLY CHARGED
AND CAN BE SAFELY DISCONNECTED.
ALTERNATIVELY,  THE BATTERY CAN REMAIN  CONNECTED TO THE CHARGER  INDEFINITELY WITHOUT OVERCHARGING| AFTER THE CHARGED  STAGE
THIS STAGE WILL SUPPLY A  PULSE CYCLE TO SAFELY  MAINTAIN THE BATTERY FOR
EXTENDED PERIODS OF TIME. IF CONNECTED FOR 10 DAYS OR  MORE WITHOUT INTERRUPTION, THE LED WILL ILLUMINATE.

| GEL (12V)| AGE (12V)| WET (12V)| CALCIUM (12V)| TIME REFERENCE
---|---|---|---|---|---
1 DESULPHATION| 11V| 11V| 11V| 11V| Max 8h
2 SOFT START| 50% Current until 12.5V| 50% Current until 12.5V| 50% Current until 12.5V| 50% Current until 12.5V| Max 8h
3 BULK| 100% Current until
14.1V| 100% Current until
14.4V| 100% Current until
14.7V| 100% Current until
14.7V| Max 24h
4 ABSORPTION| Constant 14.1V until current drops to 15%| Constant 14.4V until the current drops to 15%| Constant 14.7V until current drops to 15%| Constant 14.7V until current drops to 15%| 30 minutes
5 ANALYSE| Checks if voltage holds
at 13.2V| Checks if voltage holds
at 13.2V| Checks if voltage holds
at 13.2V| Checks if voltage holds
at 13.2V| 90sec
6 RECONDITION| Constant current (15%)
limited to 14.1V| Constant current (15%)
limited to 14.4V| Constant current (15%)
limited to 16V| Constant current (15%)
limited to 16V| 30 mins or 4 hrs depending on battery voltage (Calcium model
must enter Recondition stage)
7 FLOAT| 13.7V 100% Current| 13.7 V 100% Current| 13.7V 100% Current| 13.7V 100% Current| 10 days charge cycle
8 MAINTAIN| During 12.6V- 14.1V the
current control at 100%-20%| During 12.6V- 14.4V the
current control at 100%-20%| During 12.6V- 14.7V the
current control at 100%-20%| During 12.6V- 14.7V the
current control at 100%-20%| The charge cycle restarts if the voltage drops

Desulphation
The Desulphation stage is designed to break down sulphation that occurs in batteries that have been left discharged for extended periods of time, this process assists in revitalizing the battery.
Sulphation occurs when lead sulfate hardens and clogs up the battery cells.

Soft Start
A preliminary charge process that reduces the initial current in the battery. This protects the battery from any high start-up current from the charger and increases battery life and performance.

Bulk (Maximum Current)
Chargers the battery with the rated maximum output current until approximately 80% capacity. This stage continues until the battery’s terminal voltage has risen above the set limit (depending on battery type). If the terminal voltage has not reached the set voltage limit within the pre-set time, the charger switches to fault mode (Stage 3 LED solid) and discontinues the charging process. If so, the battery is faulty or its capacity is too large.
Absorption (Constant Voltage)
This stage ensures the battery reaches a fully charged state by gradually reducing the current and maintaining a constant voltage until the battery is 100% charged.

Analyze
An automatic battery test is conducted immediately after the absorption stage. This test monitors the battery voltage for 90 seconds to determine if the charge was successful.

• 12V charger: If the voltage is below 13.2 volts (fail), the charger will initiate the Recondition stage.
• 12V charger: If the voltage is above13.2 volts (pass), the charger will proceed to the Float Stage.

Recondition
This stage is automatically introduced if the battery is unable to hold a charge after the Analysis Stage. The Recondition Stage can recover batteries from a deeply discharged state, rejuvenating the output capacity and extending the battery life.
The Recondition stage will run for 4 hours and at the end will conduct a test to determine if the battery is now holding charge. If the battery fails this test the charger will display a fault.

Float
The Float Stage maintains the fully charged state without overcharging or damaging the battery. This means the charger can be left connected to the battery indefinitely. The battery is fully charged and can be disconnected at this stage.

Maintain
Designed to maintain the battery at 95-100% capacity over extended periods of time. The charger monitors the battery voltage and gives a Maintain when necessary to remove plate sulphation and keep the battery fully charged. This Maintain cycle is repeated infinitely over a 10-day period if left connected. If the terminal voltage drops below the set level or is disconnected, the charger automatically goes back to the beginning of the charging cycle.

SWITCHMODE TECHNOLOGY

Featuring the latest technology in battery chargers, switch-mode chargers convert 240V AC power to 12V DC power using electronic components, unlike traditional battery chargers that rely on heavy transformers. This allows the charger to be lightweight and compact without sacrificing performance.

PROTECTIVE FEATURES

POLARITY PROTECTION
Prevents the output leads from sparking due to accidental reverse connection or short circuit, making the charger safer to use around batteries.
OUTPUT SHORT PROTECTION
Short circuit connection of the clips: Check clips are not touching each other OR Check the clips are correctly connected to the battery.
NON BATTERY LINK PROTECTION
If the battery charger connects with a nonbattery load, it will go into a protection state.
DISCONNECT PROTECTION
The charger has entered the energy save mode. This happens if the charger is not connected to the battery within 2 minutes.
OVER-VOLTAGE PROTECTION
The 12V charger will automatically supply protection if the voltage is higher than 17.5V.
COOLING FAN
The charger is fitted with a fan to cool onboard electronics and maintain charging performance.

PRODUCT OVERVIEW

The 8-stage Automatic Battery Chard consists of the following components:

1. Mode button (Press/Hold).
2. Stage LED status display indicates. power, charging and fully charged.
3. Power LED.
4. Fault LED.
5. Output Voltage Display.
6. Battery-type LED.
7. Quick Connect Adaptor.| 8. 240VPower Cord.
9. Cooling fan.
10. Ground terminal.
11. Mounting flange.
12. Ventilation Grill.
13.  3.5mm mounting hole.
14.  DC Output Lead.
---|---

CHARGE STATUS INDICATOR

The ‘Charging’ and ‘Stage’ LEDs will illuminate and flash in various patterns to indicate the different Stages of Charging.
See the table below for Flashing / Solid patterns.
Note:
: SOLID
: FLASH
: OFF

| POWER ON LED| STAGE LED| FAULT LED| FAULT LED
---|---|---|---|---
Power Off| | | |
Power On| | | | 00.0
Stage| 1. Desulphation| | | | Output Voltage
2. Soft Start| | |
3. Bulk| | |
4. Absorption| | |
5. Analyse| | |
6. Recondition| | |
7. Float| | |
8. Maintain| | |
Non Battery Link Protection| | | | 00.0
Output Short Protection| | |
Output Polarity Reverse Protection| | |
Disconnect Protection| | |
Over Voltage Protection| | | | – U –
Is seriously sulfated| | (Stage 1 LED)| | Battery Voltage
Will not accept charge| | (Stage 2 LED)|
Faulty Battery| | (Stage 3 LED)|
Battery Fully Charged| | Fully Charged
(LED)|

Stage LED: illuminates and flashes when 8-stage charging is in progress and illuminates solid when fully charged. (Stage 7/8)

POWER ON LED
If the ‘Power’ LED is illuminated with a:

1. SOLID LIGHT
   The main cable is connected to the wall socket.

2. FLASHING LIGHT
   The charger has entered the energy save mode. This happens if the charger is not connected to the battery within 2 minutes.

FAULT LED – Solid Light
If the fault LED is illuminated solid, check the following:
Has charging been Interrupted in Stages 1, 2, or 3?
Restart the charger by pressing the MODE button (Press/Hold).
If charging is still being Interrupted, the battery:
STAGE 1: …is seriously sulfated and may need to be replaced.
STAGE 2: …can not accept charge and may need to be replaced.
STAGE 3: … battery is faulty and may need to be replaced. (Bulk charging
has timed out and stopped after 24 hours).

FAULT LED – Flashing Light
Charger’s Internal Temperature is too high, please turn off and disconnect the charger and let it cool down. Ensure there is adequate ventilation when charging.

SPECIFICATIONS – KACHG1212

CHARGE CONTROL
Desulphation| Maintain charge up to 11V
Soft Start| 50% current rating up to 12.5V
Bulk| 12A up to 14.1V (GEL) 14.4(AGM) 14.7V(WET) 14.7V(CALCIUM)
Absorption| Constant voltage until current drops to 1.8A
Analyze| Monitors voltage for 90 seconds
Recondition| Constant current (1MA) for 30 min or 4 hours limited to:
14.1V (GEL)
14.4(AGM)
16V(WET)
16V(CALCIUM)
Float| 13.7V also with Maintain feature
Maintain| 12.6V- 14.1 V,12-2A (GEL) 12.6V- 14.4V,12-2A (AGM) 12.6V- 14.7V,12-2A (WET) 12.6V- 14.7V,12-2A (CALCIUM)
Efficiency| App.85%
Ambient Temperature| -From 20°C to + 50°C, the output power is reduced automatically at high temperatures
Over Voltage Protection| The 12V charger will automatically supply protection if the voltage is higher than 17.5V.
BATTERY RANGE
Deep Cycle| 90 – 150Ah
Types of Batteries| Most types of lead-acid batteries including WET, MF, Calcium, AGM, and GEL
Dimension (L x W x H)| 197 x 116 x 62mm
Weight| 1.1Kg
Certifications|

*Specifications are subjected to change without prior notice.

SPECIFICATIONS – KACHG1220

CHARGE CONTROL
Desulphation| Maintain charge up to 11V
Soft Start| 50% current rating up to 12.5V
Bulk| 20A up to 14.1V (GEL) 14.4(AGM) 14.7V(WET) 14.7V(CALCIUM)
Absorption| Constant voltage until current drops to 3A
Analyze| Monitors voltage for 90 seconds
Recondition| Constant current (3A) for 30 min or 4 hours limited to:
14.1V (GEL)
14.4(AGM)
16V(WET)
16V(CALCIUM)
Float| 13.7V also with Maintain feature
Maintain| 12.6V- 14.1V,20-2A (GEL) 12.6V-14.4V,20-2A (AGM) 12.6V- 14.7V,20-2A (WET) 12.6V- 14.7V,20-2A (CALCIUM)
Efficiency| App.85%
Ambient Temperature| -From 20°C to + 50°C, the output power is reduced automatically at high temperatures
Over Voltage Protection| The 12V charger will automatically supply protection if the voltage is higher than 17.5V.
BATTERY RANGE
Deep Cycle| 150 – 300Ah
Types of Batteries| Most types of lead-acid batteries including WET, MF, Calcium, AGM, and GEL
Dimension (Lx Wx H)| 217 x 116 x 62mm
Weight| 1.28Kg
Certifications|

CHARGING INSTRUCTIONS

Settings are made by pressing the MODE button (Press/Hold). After about two seconds the charger activates the selected program. The selected program will automatically default to the AGM Mode next time the charger is connected
STEP 1 – CHECK THE ELECTROLYTE LEVEL
Please ensure to check the electrolyte level prior to charging the battery by removing the vent caps (not required on sealed & maintenance-free batteries.The electrolyte level should be 6mm (1/4″) above the battery’s plates. If low, use distilled water to top up to the correct level and refit the vent caps.
STEP 2A – CONNECTING TO BATTERY OUT OF VEHICLE
Connect the RED Output Lead (Battery Clip from the charger to the Positive (+) Battery Terminal) and ensure a good connection is made.
Connect the BLACK Output lead (Battery Clip from the charger to the Negative (-) Battery Terminal) and ensure a good connection is made.
Alternatively if connecting via the Chargers Output Plug, make sure the polarity of the external plug is correct before connecting.

STEP 2B – CONNECTING TO THE BATTERY IN THE VEHICLE
Before connecting, determine if the vehicle is Negative (-) or Positive (+) Earthed.
Negative earthed vehicles are most common and use the chassis as an Earth by connecting the Battery Negative Terminal to a conductive chassis point.
The purpose of connecting the charger through the chassis is to eliminate any power spikes going through the vehicle’s sensitive electrical system.
If you are unsure, please seek advice from a qualified person before connecting.

NEGATIVE EARTHED CONNECTION (Most Vehicles)

Connect the RED Output Lead (Battery Clip) from the charger to the Positive (+) Battery Terminal and ensure a good connection is made.
Connect the BLACK Output Lead (Battery Clip) from the charger to a clean conductor point on the vehicle’s chassis away from any fuel lines or moving parts.

POSITIVE EARTHED CONNECTION

Connect the BLACK Output Lead (Battery Clip) from the charger to the Negative (-) Battery Terminal and ensure a good connection is made.
Connect the RED Output Lead (Battery Clip) from the charger to a clean conductor point on the vehicle’s chassis away from any fuel lines or moving parts.

CHASSIS EARTHING (Not Essential)

The chassis earthing terminal should be connected to an earthing point which will be depending on where the battery charger is installed. In a vehicle, connect the chassis ground terminal to the chassis of the vehicle. In a boat, connect to the boat’s grounding systems. In a fixed location, connect to an earth stake. This connection is not essential but may increase efficiency.

STEP 3 – CONNECT TO 220-240V AC MAINS POWER
Connect the battery charger to a certified 220-240V AC mains power socket and turn on the mains power.

STEP 4 – CHARGING PROCESS
During the charging process, the ‘Charging’ and ‘Stage’ LEDs will flash various patterns. This is normal and indicates the various charging stages. Refer to “How do I know what stage the battery charger is in” in the FAQ section, page 18.
When the ‘Stage’ LED remains on (this is known as the Float Stage) the charger can be left connected to the battery indefinitely without overcharging.
Alternatively, the battery can be disconnected at this point as it is fully charged.
If the ‘Power On’ LED is flashing, there is a fault; refer to the “Fault Codes” explanation on page 17 of this manual.

STEP 5 DISCONNECTING THE CHARGER FROM BATTERY
Ensure the 220-240V AC mains switch is turned off and the charger is disconnected from the 220-240V AC mains power.
Battery out of the vehicle:
Remove the BLACK Output Lead (Battery Clip) from the Negative (-) Battery Terminal.
Remove the RED Output Lead (Battery Clip) from the Positive (+) Battery Terminal.
Battery in vehicle
Remove the Output Lead (Battery Clip) from the chassis connection.
Remove the Output Lead (Battery Clip) from the Battery Terminal.

MOUNTING INSTRUCTIONS

This 8-stage charger is designed for indoor use only and not outdoor conditions (rain and moisture). Ensure that both the charger and battery are in a well-ventilated area during
charging.
If permanently fixed, the charger should be mounted to a suitable vertical or horizontal panel, with at least 10cm clearance from the end plates to provide adequate ventilation for the cooling fan.
The battery charger is molded with end plates that include a mounting flange for easy mounting.

PERMANENT WIRING TO BATTERY

If required, It is possible to hard wire the DC charging Output Leads to the battery for permanent installations.
You will need an Adaptor Lead with Ring Terminals, Fuse, Fuse Holder, and a suitable Plug to attach to the current Charger Plug.
Alternatively, if you would like to install this yourself please follow the steps below:

1. Cut off the supplied battery clips; ensure you leave a sufficient cable to reach the battery terminals. (DO NOT extend the battery charger DC output cables, as the added voltage drop will cause incorrect charging).
2. Fit a ring terminal to the BLACK Negative (-) wire.
3. Connect the In-line fuse to the RED Positive (+) wire.
4. Connect a ring terminal to the other end of the in-line fuse.
5. Connect the RED Output Lead (with in-line fuse and ring terminal) to the Positive (+) battery post.
6. Connect the BLACK lead (with ring terminal) to the Negative (-) Battery Terminal.
7. Fit the correctly rated fuse. (Recommended: Double the charger’s current rating)

If the charger is used in a Permanent / Hard Wired application and the vehicle will not be used for extended periods of time, it is best to leave the charger connected to mains power (turned ‘On’) so that it can maintain and keep the battery fully charged.
Ensure any modification to the 220-240V AC mains lead is carried out by a qualified person and that connection to the mains supply is in accordance with the National wiring rules.

CHARGER REFERENCE: 12 / 24 VOLT BATTERY

Please Note:
It is recommended to use a charger with an output of at least 10% of your total Battery Amp Hour Capacity.
(Example – 120Ah Battery is Recommended to have at least a 12 Amp Charger)

FAULT CODES

The 8 Stage Charger Technology features high-quality internal sensing components to determine any issues with the battery or charger. Various Fault Codes will be displayed on the charger for reference.
The Fault Codes will be displayed in the following way:

Error Code| Power-On LED| Stage LED| Fault LED| Cause| Remedy
---|---|---|---|---|---
Reverse Polarity
/ Output Short| | | | Short circuit or reverse
connection of the clips| Check clips are not touching each other OR Check the clips are correctly connected to the battery.
Non Battery Link| | | | Nonbattery link| Please choose the correct battery type for the connection.
The charger is NOT a Power Supply.
Faulty Battery| | Stage 3 (LED)| | Bulk charging has timed out and stopped after
24 hours.| The battery is faulty and may need to be replaced. Please
get tested by a Qualified Person
Over Voltage| | | | 12V battery:
Voltage is above 17.5V.| Disconnect the charger and check the battery voltage.
This charger is suitable for 12V batteries only.
Over Temperature| | | | The internalTemperature
is too high| Turn off the charger and allow it to cool.
Ensure there is adequate Ventilation

FREQUENTLY ASKED QUESTIONS

Q. How do I know if the battery is charged?
A. The charger’s ‘Charged’ and/or ‘Maintain’ LED (Stage 7/8) will be illuminated (solid). Alternatively use a Battery Hydrometer (if caps are removable). A reading of 1.250 or more in each cell indicates a fully charged battery.
Q. I have connected the charger properly but the ‘STAGE LED’ does not come on?
A. In some cases, batteries can be discharged to the point where they have very little or no voltage (Not recommended and may void warranty). This can occur if a small amount of power is used for a long time, for example, An interior light is left on for an extended period of time or an electrical appliance without a ‘voltage cut-out’ is unknowingly connected.
Q. What minimum voltage will the charger need to sense?
A. Although a battery is not designed to be discharged below 10.5 Volts (12 Volt System) under load, the 8-Stage chargers are designed to charge from as little as 7.0 Volts (12V charger).
If the battery voltage is lower than this, use a pair of booster cables to connect an external battery with the same voltage in parallel. This should provide more than the required
volts to the battery being charged. The charger can then start to charge the battery and the booster cables can be removed.
Q. Can I use the charger as a power supply?
A. 8-Stage chargers are designed to supply power to the battery clips Only when they are connected correctly to a battery. This is to prevent sparks during connection to the battery or if connected incorrectly by mistake. This safety feature prevents the charger from being used as a ‘Power Supply’.
No Voltage will be present at the clips until connected to the battery.
Q. How do I know what stage the battery charger is in?
A. Below are the conditions that are displayed by the ‘Stage’ LED for each of the charge stages:

| 1 Desulphation| 2 Soft Start| 3 Bulk| 4 Absorption| 5 Analyze| 6 Recondition| 7 Float| 8 Maintain
---|---|---|---|---|---|---|---|---
Stage| | | | | | | |

Q. What if I have a question that has not been answered?
A. Please contact the supplier for any further questions or advice.

CAUTION
ALWAYS PLACE THE BATTERY CHARGER IN AN ENVIRONMENT THAT IS:
A. WELL VENTILATED.
B. NOT EXPOSED TO DIRECT SUNLIGHT OR HEAT SOURCE.
C. OUT OF REACH FROM CHILDREN.
D. AWAY FROM WATER / MOISTURE, OIL, OR GREASE.
E. AWAY FROM ANY FLAMMABLE SUBSTANCE.
F. SECURE WITH NO RISK OF FALLING.

SAFETY

The charger is designed for charging 12V Lead-Acid, AGM, Gel, and Calcium Batteries. Do not use the charger for any other purpose.

• Check the charger cables prior to use. Ensure that no cracks have occurred in the cables or in the battery clips. A charger with damaged cables or clips must not be used. A damaged cable or clip must be replaced by a professional representative.
• Never charge a damaged battery.
• Never charge a frozen battery.
•  Never place the charger on top of the battery when charging.
• Always allow for adequate ventilation during charging.
• Avoid covering the charger.
• A battery being charged could emit explosive gases. Prevent sparks close to the battery. When batteries are reaching the end of their life-cycle internal sparks may occur.
• All batteries fail sooner or later. A battery that fails during charging is normally taken care of by the charger’s advanced control, but some rare errors in the battery could still exist. Don’t leave any battery during charging unattended for an extended period of time.
• Ensure that the cabling is not obstructed or come into contact with hot surfaces or sharp edges.
• Battery acid is corrosive. Rinse immediately with water if acid comes into contact with skin or eyes, and seek immediate medical advice.
• Batteries consume water during use and charging. For batteries where water can be added, the water level should be checked regularly. If the water level is low, add distilled water.
• This appliance is not designed for use by children or people who cannot read or understand the manual unless they are under the supervision of a responsible person to ensure that they can use the battery charger safely. Store and use the battery charger out of the reach of children, and ensure that children cannot play with the charger.
• Connection to the mains supply must be in accordance with the national regulations for electrical installations.

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