12V
Battery
Charger
HU6560
Charging Current
16 Amp
(Total)
4 Banks
4
x
4 Amp
5
Stage
Charging
Battery Capacity
1.2-120Ah
User Manual
For Lead Acid Batteries
Manufactured and Packaged for
Automotive Imports Pty Ltd
22 - 28 Lexton Road, Box Hill, Victoria, Australia
Made in China
AUS:
www.hulk4x4.com.au
NZ:
www.hulk4x4.co.nz
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3
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14
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Fig.2: Control Panel
Charging Phases
................................................
..................9
Diagnosis & Recovery..........................
..................................9
Bulk......................................................
................................10
Bulk Charging Time
.........................................
...................10
Absorption............................................
................................10
Trickle Charge.....................................
.................................10
Maintenance Charge............................
................................10
Trouble Shooting
..........................................
.......................11
Maintenance
.....................................................
..................12
Equipment
........................................................
...................12
Mounting & Product Dimensions
...................
...................12
Technical Data
............................................
.........................13
Declaration of Compliance
................................................14
Application
.......................................................
...................14
Environmental friendly disposal
..................
....................14
For Your Safety
...................................................................2
Product Feature
..................................................................2
Product Safety Feature
..........
............................................2
Overheating Protection.......................
..................................2
Safety Information
...................................
...........................3
Contents
.........................................................
.....................4
Equipment Description..........................................
...............5
Component Description.........................
...............................5
Indication..............................................................................6
Operation
......................................................................7- 8
Charging Batteries..............................
..................................7
DC Output Cable Wiring Diagrams........................
...............7
Select Charging Mode................
..........................................8
Reset/Deleting Settings........................................................8
Switching Over Between Modes 1,2 and 3.
..........................8
MODE 1 (14.4V/0.8A)............
........................8
MODE 2 (14.4V/4.0A)............
........................8
MODE 3 (14.7V/4.0A)............
........................8
Index
Index
Fig. 1: Equipment Description
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Safety Information
•
HULK Professional Battery Charger
charger is designed for charging 12V 1.2-120Ah Lead-Acid rechargeable batteries.
Do not use it to supply power to low voltage electrical system other than designated applications. Do not use it for any other purposes.
It may cause an explosion.
WARNING! DO NOT ATTEMPT TO CHARGE A NON-RECHARGEABLE BATTERY (PRIMARY CELLS).
• Before charging make sure the input power is as per rated specifications, otherwise the charging performance may be seriously
affected.
•
Do not
use the battery charger for charging dry-cell batteries. They may burst and cause injury to persons and damage to property.
• Never charge a frozen battery.
• Never charge a damaged battery.
•
Do not
use the charger with a damaged cable
24
. It must be replaced by the manufacturer, its service agent or similarly
qualified technician in order to ensure safety.
•
Do not
operate the charger if it appears to be damaged or malfunctioning. Take it to qualified person for inspection and repair.
•
Do not
disassemble charger, the incorrect reassembly may result in electric shock or fire. Locate charger as far away from
battery as DC cable permit.
• Never place the charger above battery being charged, gases from battery will corrode and damage charger.
• While charging always use safety glasses, gloves, protective clothing and keep your face away from the battery.
• Remove 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 melt such metallic objects, causing a severe burn.
• Explosion hazard! A battery being charged could emit explosive gasses. Avoid smoking or open sparks or flames in the vicinity of the
battery. Explosive and flammable substances such as fuel or solvents should not be kept in the vicinity of the charger or the battery.
• Disconnect the supply before making or breaking connections to the battery. While connecting the charger to the battery, maintain
correct polarity connection and avoid short-circuiting. Connect the appropriate DC clip to the battery post which is not connected
to the automobile chassis.
(The battery terminal not connected to the chassis has to be connected first.)
Connect the other DC
connector to the chassis, away from the battery and fuel line. The connector to be fixed to the positive pole shall be coloured red
and that to be connected to the negative pole shall be coloured black. Then connect the battery charger to the supply mains.
Product Features
Congratulations on your purchase of the
HULK Professional 4 Bank Battery Charger
is designed for charging simultaneously and
independently up to 4x12 Volt lead-acid rechargeable batteries, widely used in motorbikes, cars etc. The
HULK Professional Battery
Charger
also charges batteries in cold conditions. Using state-of-the art technology, the charger enables the recharging of the batteries
to almost 100% of their original capacity. It recovers slightly sulphated batteries. It provides trickle charge and maintenance charging
which increases battery life and gives superb performance. It also features low back current drain and low ripple.
Locate Charger
• Locate the charger as far away from battery as the DC cord permits.
• While charging do not place the charger directly above or below the battery. Gases or fluids from the battery may corrode
and damage the charger.
• Never allow battery acid to drip on the charger
Fig 3: Four 12VDC Battery configuration
1 2 3 4
AC POWER
DC POWER
16
Amp
For 4 x 12 Volt
DC Batteries
* Series connections must be removed during charging
OPERATION
DC Output Cable Wiring Diagrams
HULK Professional Battery Charger
. Each DC jacketed bank cable
must be properly connected to independent 12VDC battery and observe
the polarity of all connections. Series connection wire must be removed
during charging. Please refer to our typical wiring diagram.
Charging Batteries
1)
Charging of a battery permanently installed in a vehicle.
a)
Before connecting or disconnecting the battery leads, the power cord should be removed from the mains.
b)
Check polarity of the battery post. A positive (“+”) battery post usually has a larger diameter than a negative (“-”) post.
c)
Identify the pole of the battery that is connected to the chassis (earth). Normally the negative terminal is connected to the chassis.
d)
Charging of negative earthed battery:
• Connect the red wire (“+”) to the positive (“+”) pole of the battery and the black wire (“-“) to the vehicle chassis or
non moving engine part.
e)
Charging of positive earthed battery:
• Connect the black wire (“-”) to the negative (“-”) pole of the battery and the red wire (“+“) to the vehicle chassis or
non moving engine part.
2)
Charging of a battery not connected to a vehicle
a)
Before connecting or disconnecting the battery leads, the power cord should be removed from the mains.
b)
Connect the red wire (“+”) to the positive (“+”) pole of the battery and the black wire (“-“) to the negative (“-“) pole.
(For multi-Bank charging, connect the red wire , , , (“+”) to the positive (“+”) pole of the battery and the black wire
, , , (“-“) to the negative (“-“) pole)
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35 37 39
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38 40
Wiring diagrams of
HULK Professional Battery
Charger
Quadruple output charger for 4 batteries
Reset / Deleting Settings
After connection to the power supply and turning ON the switch , the charger automatically resets itself to basic settings and
remains in low power mode unless further action is executed by the user.
5
Select Charging Mode
Power ON/OFF
Plug the AC lead to a 220~240VAC outlet. By pressing On/Off Power button power will turn on and it will be indicated by the
red illumination of the mode button . Power will turn off if power button is pressed again. Red LED will turn off.
To charge various batteries at different ambient temperature you can select the correct voltage charging mode by pushing the
selection button of charging station(s) 1 to 4 until the light for the correct voltage is lit.
Charging stations 1 to 4 can be used independently or simultaneously. Selection button(s) will illuminate blue.
6
5
5
6
6
Charger
Detachable mounting
brackets
Mounting holes
Mains cable with
power plug
Built-in female
connectors
Detachable lockable
male connectors
“+” Pole quick clamp (red)
“-” Pole quick clamp (black)
Indication Description
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16 17
18 19 20 21 22 23
25
26
27
28
29
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31 32
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40
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Component Description:
MODE 1 (14.4/0.8A)
This mode is suitable for charging small batteries with a capacity below 14Ah.
MODE 3 (14.7/4.0A)
This mode is mainly applied for charging large batteries with a capacity over 14Ah in cold conditions or charging several AGM
batteries with capacity of more than 14Ah.
MODE 2 (14.4/4.0A)
This mode is mainly applied for charging large batteries with a capacity over 14Ah in normal conditions.
Overheating Protection
HULK Professional Battery Charger
charger is protected by NTC control. During the charging process, if the charger becomes
too hot or due to extreme ambient temperature, the power output is automatically reduced to protect itself from damage.
The charger continues to trickle charge and charger increases power automatically when the ambient temperature drops.
Bulk Charging Time
Technical Data
* = Back current drain is the amount of current drawn by the charger from battery, when the charger is connected to the battery, without power
cord connected. HULK Professional Battery Charger has extremely low back current drain which corresponds to 0.7 Ah per month ( 1mA/hr).
** = A high current ripple heats up battery and reduces life of battery. Against a linear charger, which has a ripple of up to 400%, HULK Professional
Battery Charger’s ripple is below 2%, which is much lower than the max 5% for a sealed acid battery. Equipment connected to the battery could be
damaged by high voltage ripple.
Charging Phases
HULK Professional Battery Charger
charger performs 5-step fully automatic charging cycle.
16 Amp
Trickle
Time
1) Diagnosis & Recovery:
When a charging instruction is given to the charger, the unique diagnostic function automatically checks status of battery
(detects voltage). If a deeply discharged battery’s voltage is over 3.0V±0.5V the charger begins pulse charging with small
current to recover it, which terminates when voltage reaches to 10.5V±0.5V. If battery voltage is over 10.5V±0.5V the charger
skips pulse charging and switches over to pre-selected charging mode.
3) Absorption:
A constant low charging current is applied at 0.8A to raise voltage
from 14.1V to 14.4V. In this phase complete charging up to almost
100% is achieved. The Charger switches to float charge phase
after
sensing that the battery is fully charged.
5) Maintenance Charge:
If the battery is loaded and/or terminal voltage falls below 12.8V,
the charger starts a maintenance charging pulse at constant 0.8A
until voltage reaches 14.4V. The maintenance charging is discontinued.
Cycle of trickle charging and maintenance charging is repeated
indefinitely to keep battery in good condition when it is not in use
and enables charger to be left connected indefinitely.
4) Trickle Charge:
The battery is fully charged and ready to use. The battery will signal
to the charger and will only take enough current to sustain small
loads such as alarms etc or current leaks in the vehicle wiring
circuit. Very low current of 200mA is given to the battery. When
voltage drops below 12.8V, the monitoring circuit senses that
battery needs more current to maintain its charge than available
in float charge phase. The Charger switches to the Maintenance
Charge phase.
2) Bulk :
80%
of energy is returned in this phase of charging.
Here charger performs in two-stages-
a) High Rate Charging:
Charger delivers constant current
of 4.0A until the voltage reaches to 12.8V
b) Medium Rate Charging:
Charger delivers reduced
constant current until the voltage reaches to 14.1V at
which point the charger switches to Absorption phase.
Trouble Shooting
Charger does
not work
Charger has
no DC output
No charging
current
Excessive
charging time
a) plug in
b) Check AC connections and make sure
mains are switched on
c) Check receptacle
a) Check DC connection between charger
and battery and make sure they are not
short circuited
b) Check clamps or ring connectors are
connected to the correct polarity
c) Check connectors are not greasy or
corroded and making a clean connection
and there are no loose or damaged
connections
d) Press the MODE button
a) Check battery condition
b) If battery can not be de-sulfated, it
must be replaced
a) Check battery type selection
b) Battery can not be charged and must be
replaced
a) Charger is not plugged in
b) Poor electrical connection
c) AC outlet is dead
a) Battery is connected with
reverse polarity poles
b) Output is short circuited
c) Poor contact from charger
to battery
d) MODE button is not pressed
a) Battery may be defective/
excessive current draw
b) Battery may be severely
sulfated
a) Wrong battery type selected
b) Battery capacity too large
Indicator lights
are not on
Or
All LED
indicators
work normally
Maintenance
The
HULK Professional Battery Charger
does not need any
specific maintenance. Only install, maintain or service this charger
when it is disconnected from the mains. It may be cleaned with a dry
cloth or soft tissue. Do not use any solvents or other cleaning agents.
Mounting & Product dimensions
The charger is easy to mount using screws. The charger is
supplied with a pair of bracket containing 4 holes. Two additional
built-in hangers are also provided.
63.0±0.5mm
260.0±1.0mm
246.0±1.0mm
Equipment
The
HULK Professional Battery Charger
is supplied with four
detachable and lockable snap connected, colour coded lead sets
with clamps for bench charging.
Environmental friendly disposal
You can help protect the environment! Please remember to respect your local regulations. Please hand over the non-working
electrical equipment to an appropriate waste disposal centre. The packing material is recyclable.
Declaration of Compliance
Conforms to EN55014-1, EN55014-2, EN61000-6-1, EN61000-3-2, EN61000-3-3, EN60335-1, EN60335-2-29, EN 62233.
Application
Note: We reserve right to carry out technical modifications for improvement of 4x4 Amp - 16 Amp Total Charger.
• Do not cover the charger while charging.
• Do not touch the battery clips together when charger is connected with mains.
• Charging must be ceased immediately if battery is found to be too hot or leaks out liquid during charging.
• In case of malfunction or damage, immediately disconnect the charger from the mains.
• Do not use vehicle when charging permanently installed batteries.
• During charging the battery must be placed in a well ventilated area.
• Danger of chemical burns! Battery acid is highly corrosive. If your skin or eyes come into contact with acid, immediately rinse the
affected part of the body with excessive water and seek medical advice.
• The battery terminal not connected to the chassis has to be connected first. The other connection is to be made to the chassis, far
from the battery and fuel line. The battery charger is then to be connected to the power supply.
• After charging, disconnect the battery charger from supply mains. Remove the chassis connection and the battery connection,
respectively. This will reduce back drain current.
• This appliance is not intended for use by persons 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.
• Keep away from children.
• Ensure that charger switches to maintenance charge mode, before it is left unattended and connected for long time.
Switching over between Modes 1, 2 and 3
By repeatedly pressing the selection button it displays the charging modes in the following order-
MODE 1 , MODE 2 , MODE 3
and repeats this cycle.
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If you press
⑥
, charging mode automatically switches to the next operation mode and begins functioning in that specific mode.
However after a full charge, if the battery is not disconnected from the charger, it remains in float charge mode, even if user switches
it over to another mode. This protects battery from being damaged.
6
Equipment Description
Indication Symbol Description
Red LED ON for “ POWER ”
In case of open circuit or short circuit or reverse connection, LED lights up
Blue light ON for “ Mode ” selection
Red LED displays “ Mode1 ” (14.4V/0.8A)
Red LED displays “ Mode 2 ” (14.4V/4.0A )
Red LED displays “ Mode 3 ” (14.7V/4.0A )
Red LED displays “ Incorrect polarity “
Red LED flashes “ Charging in progress ” (Below 25%)
Red LED ON, Red LED flashes “ Charging in progress ”
(Between 25% to 50%)
Red LEDs , ON, Red LED flashes “ Charging in progress ”
(Between 50% to 75%)
Red LEDs , , ON, Green LED flashes “ Charging in progress”
(Between 75% to 100%)
Red LEDs , , ON, Green LED ON “Charging completed”(100%)
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11
12 13
11 12 13 14
11 12 13 14
11 12 13
11 12 13
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14
11 12
11
12
13
Indication:
Input Voltage AC
Output Voltage
Starting Current
Input Current
Charging Voltage
Charging Current
Back Current Drain*
Ripple**
Ambient Temperature
Type of Charger
Type of Batteries
Bank Configuration
Number of Batteries can be
charged simultaneously
Battery Capacity
Housing Protection
Weight
Noise Level
220-240VAC, 50/60Hz
Nominal: 12V
<25 A (No AC input)
2.4A RMS max
14.4V±0.25V or 14.7V±0.25V
16 Amp ( 4.0A±10% or 0.8A±10% per Bank)
5 mA
Max 150mV
0°C to 40°C, Reduced output power at higher temperature
Five step, fully automatic, switch mode with maintenance charging
12V Lead-acid rechargeable batteries (WET, MF,AGM and GEL)
Quadruple
4
1.2-120Ah
IP64 (Dust and Splash proof)
2.3kg
<50 dB (Tested from a distance of 50cm)
MODEL 16 Amp
Product Safety Features
• Electronically safe against user errors. The charger will not damage vehicle electronics. It is totally safe for permanent connection
and maintenance of irregularly or seasonally used batteries even while the battery is still connected to the vehicle.
It provides optimal condition without damage. No risk of over-charging!
• Full protection against wrong connection and against short circuit ensuring safe charging operation.
• Provided with Spark protection mechanism. The charger will not begin operation upon connection to the battery unless a charging
mode has been selected. This embedded feature eliminates the possibility of a spark that often appears during connections.
• Fully controlled by internal MCU (Micro-Computer-Unit), which makes it faster, powerful, more reliable and smarter.
It detects the state of charge of the battery and initiates charging.
• Dust and splash proof (IP64), approved for outdoor use.
• Double insulated.
Contents
1)
HULK Professional Battery Charger
2) 4 - Sets Quick connect battery leads with clamps
3) 1 - Pair Mounting brackets
4) 6 pcs of stainless steel Ø8 x 25mm flat Phillips countersunk head screws and wall plug set
5) User Manual
For Your Safety
This manual contains important safety and operating instructions. Read this manual carefully before using the charger for the first
time and keep the manual in a safe place for future reference.
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5
10
Problem
Solution
Possible Cause
Indication
Car
Boat
ATV
Motorcycle
Golf Cart
SUV
148.6mm
105mm
