6/12/24V 40A 8 STAGE AUTOMATIC
CHARGER & BATTERY MANAGER
WORKSHOP
P/No. HDBM4000
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IMPORTANT SAFETY INFORMATION
Please read this manual thoroughly before use and store in a safe place for future
reference.
WARNINGS
• Explosive gases. Prevent flames and sparks. Provide adequate ventilation during
charging.
• Before charging, read the instructions.
• For indoor use. Do not expose to rain.
• For charging lead acid batteries ONLY (of the size & voltage specified in the
specifications table).
• Always charge the battery on the correct voltage setting. Never set the charger to a
higher voltage than the battery.
• Disconnect the 240V mains supply before making or breaking the connections to
the battery.
• The battery charger must be plugged into an earthed socket-outlet.
• Connection to supply mains is to be in accordance with National wiring rules.
• Do not attempt to charge non-rechargeable batteries.
• Never charge a frozen battery.
• If the AC cord is damaged do not attempt to use. It must be replaced or repaired by
a qualified person.
• Corrosive substances may escape from the battery during charging and damage
delicate surfaces. Store and charge in a suitable area.
• Ensure all vehicle accessories including lights, heaters, appliances etc are turned off
prior to charging.
• This charger is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
• Young children should be supervised to ensure that they do not play with the
appliance
• Only use the hanger bolts provided with the docking station to mount on the back of
the charger
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INDEX
1. Features Page 4
1.1 Specifications Page 6
1.2 Product Overview Page 7
1.3 Assembly/Set Up Page 9
2. Operation Page 10
2.1 Setting Battery Voltage Page 11
2.2 Pulse –Tronic Charge Page12
2.2.1 Charge Function Modes Page 12
2.2.2.1 Storing Pulse-Tronic Charge Page 14
2.2.2.2 Storing Supply/Diagnostic Mode Page 14
2.3 Battery and Alternator Test Page 15
2.3.1 Battery Test Page 15
2.3.2 Charge System Test (Alternator) Page 16
2.3.3 Battery Starting Charge Capacity (CCA) Page17
2.4 Battery Maintenance Page 18
2.4.1 Desulfation Page 19
2.4.2 Equalisation Page 19
2.5 Power Supply Page 21
2.5.1 Diagnostic Page 22
2.5.2 Supply Page 23
2.6 Engine Start Page 25
2.6.1 Procedure Page 25
2.7 Alarms Page 26
3. FAQ’s Page 27
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1. FEATURES
AUTOMATIC 8 STAGE CHARGING
Automatic 8 stage charging delivers a complete and thorough charge giving your
batteries longer life & better performance. Once the battery is fully charged, the
battery charger will continue to monitor the battery without the risk of overcharging.
STAGE 1: Checks battery settings with battery
STAGE 2: Desulphation stage is designed to break down sulphation occurring in
batteries that have been left flat for extended periods of time, returning them back
to full charge. Sulphation occurs when lead-sulphate hardens and clogs up the
battery cells.
STAGE 3: Soft Start, This is a preliminary charge process that gently introduces power
to the battery, protecting the battery and increasing battery life.
STAGE 4: Bulk stage reduces charging time by charging the battery at the maximum
rate (constant current) to a set voltage, at which point the battery is approximately
80% charged.
STAGE 5: Absorption stage charges the battery to 100% by adjusting the charge rate
allowing the battery to absorb more power.
STAGE 6: Analysis mode tests the battery to ensure that it has taken the charge;
if the battery passes the test the charger will proceed to the float stage, but if the
battery fails the test, the charger will apply a recondition charge to try to return the
battery to full charge.
STAGE 7: Float stage maintains the battery at 100% charge without overcharging or
damaging the battery.
STAGE 8: Pulse Float, provides a long term storage charge to the battery by only
providing charge when required.
ENGINE START FUNCTION
Starts vehicles with a flat battery after a controlled 5 minute charge.
LCD DISPLAY
The battery charger is fitted with an LCD digital display that displays the,
battery voltage & Amp readings, correct connection and other warning messages
during operation.
V
12345678
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AUTO/MANUAL ADJUSTABLE OUTPUT
Manually or use the Automatic charge setting feature to adjust the rate of charge to
best suit different battery sizes.
MULTI VOLTAGE OPERATION
Suitable for charging 6V, 12V & 24V batteries.
SHORT CIRCUIT & POLARITY PROTECTION
POWER SUPPLY MODE
Supply Power to the vehicle whilst the battery is being changed.
DIAGNOSTICS POWER SUPPLY
Supplies stabilised power to the vehicles MCU whilst receiving software updates.
BATTERY CHEMISTRY SELECTION
The Multi-Chem function allows you to set the charging profile to suit each battery’s
chemistry type (GEL, AGM, WET and Calcium). This ensures correct and thorough
charging and maximises battery performance and battery life. The following section
describes the charge profiles for each chemistry type.
MANUALY SET EQUALISATION
Manually configure an Equalisation routine to balance all the cells of the battery.
MANUALY SET DESULPHATION
Manually perform Desulphation on the battery.
BATTERY AND ALTERNATOR TESTING
Test Battery Voltage.
Performs a check on the Alternator.
Checks the battery while starting.
SILENT MODE
The charger can run with the fan turned off where it is important for the charger to
be running silent, like a car show room.
OPTIONAL 6 & 10 METRE LEADS
Optional 6 or 10 metre battery leads can be purchased for applications where longer
leads are required.
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1.1 SPECIFICATIONS
P/No. HDBM4000 6V 12V 24V
Type 8 Stage Automatic
Input 240V, 50Hz, 600W
Output 3-40A 3-40A 3-20A
Engine Start – 70A for 3 sec –
Minimum Start 2.0V 2.0V 2.0V
Voltage
Charge Voltages (Absorption)
AUTO 7.2V 14.4V 28.8V
AUTO i 7.7V 15.4V 30.8V
GEL 7.2V 14.4V 28.8V
AGM 7.35V 14.7V 29.4V
WET 7.7V 15.4V 30.8V
Calcium 8.0V 16.0V 32.0V
Float Voltage 6.7V 13.5V 27.0V
Back Drain 20mA 50mA 80mA
Approvals Electrical Safety, EMC
Type 6 & 12V 24V Time
Battery Range Battery Range
Automotive (CCA) 100 3700 100 2000 6 – 15
Marine (MCA) 120 4600 120 2300 8 – 18
Deep Cycle (AH) 14 600 14 300 7 – 17
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1.2 PRODUCT OVERVIEW
Figure A
1 2 3 4
5
6
18
17
16
20
19
711 91015 13 1214 8
21 2322
1. Display of the set battery voltage value.
2. Main display. Display: measured battery voltage, current, Ah selection, voltage
value selected for the Supply / Diagnostic / Equalization programs, interface
messages for the operator, alarm codes.
3. Polarity inversion, short circuit, worn out or faulty battery alarm.
4. Set current, voltage and Alarm codes“AL1 - AL9”
5. Battery charge level.
6. Choice of the Pulse Tronic charge current:
AUTO, BOOST, Customised (Ah setting).
7. Low temperature function “COLD”.
8. “SILENT NIGHT” function.
9. EQUALIZATION mode.
10. DESULFATION mode.
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11. Choice of the battery production technology:
WET: lead-acid batteries with liquid electrolyte;
GEL: lead-acid batteries, sealed, with solid electrolyte;
AGM: lead-acid batteries, sealed, with electrolyte on absorbent material;
PbCa: lead-calcium batteries.
12. SUPPLY mode.
13. DIAGNOSTIC mode.
14. PULSE TRONIC charge process phases.
15. START mode.
16. Automatic charge mode.
17. Pulse Tronic charge.
18. Alternator Test Function.
19. Battery starting capacity test.
20. Battery charge status test.
21. BATTERY VOLTAGE – Settings button:
– Battery voltage 6/12/24V.
– Silent mode.
– Voltage/Current adjustment.
22. MODE – Settings button:
– Pulse Tronic CHARGE (AUTO, AUTO d, WET, GEL, AGM, PbCa).
– TEST (battery status, vehicle alternator, battery starting capacity).
– Advanced Programmes (DESULFATION, EQUALIZATION, DIAGNOSTIC, SUPPLY).
– Voltage/Current adjustment.
23. CHARGE RATE – Settings button:
– Output current (AUTO, BOOST, customised);
– START mode.
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1.3 ASSEMBLING CHARGING LEADS TO BATTERY CLAMPS
The HDBM400 battery charger is shipped with the battery clamps disconnected from
the positive & negative charging leads.
IMPORTANT:
• The negative (Black) battery clamp must be connected to the charging lead with
the black heat shrink on the lug.
• The positive (Red) battery clamp must be connected to the charging lead with the
red heat shrink on the lug.
To connect both the positive and negative leads to the battery clamps refer to the
instructions below:
1. Remove the M6 Dome head bolt from the clamp.
2. Fit the lug on the end of the charging lead to the battery clamp.
3. Tighten the lug.
1.3.1 CABLE CALIBRATION: the possibility of using different length charging
cables requires initial calibration so as to compensate the drop in voltage along
the cables.
CALIBRATION PROCEDURE
– press and hold the BATTERY VOLTAGE button (fig. A.21) and plug the cable into
the mains socket;
– continue to hold the BATTERY VOLTAGE button (fig. A.21) until the digits “3 m”
or “6 m” or “10 m” flash on the display;
– select the required value using the MODE button (fig. A.22);
– wait 5” for the selection to be confirmed.
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