PERFECTCHARGE IU6 - Battery charger WAECO - Free user manual and instructions
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USER MANUAL PERFECTCHARGE IU6 WAECO
We will be happy to provide you with further information about WAECO products. Please order our free catalogue with no obligation to buy on our homepage: www.waeco.com
Please read this instruction manual carefully before starting the appliance and keep it in a safe place for future reference. If you pass on the appliance to another person, hand over this operating manual along with it.
Contents
1 Notes on using the manual 28
2 Safety instructions 29
2.1 General safety 29
2.2 Operating the device safely 30
2.3 Safety precautions when handling batteries 31
3 Scope of delivery 32
4 Intended use 32
5 Technical description. 33
5.1 Function 33
5.2 Displays and controls 33
5.3 Battery terminals and cables 34
6 Using the charger 34
6.1 Connecting the charger 34
6.2 Charging the battery 36
6.3 Disconnecting the charger 38
7 Troubleshooting 39
8 Cleaning and maintenance 40
9 Guarantee 40
10 Disposal. 40
11 Technical data. 41
12 Hints on handling batteries 42
12.1 What you should know about batteries. 42
12.2 Choosing the correct battery. 42
12.3Charging the batteries properly 44
12.4 Avoiding battery failure 45
1 Notes on using the manual
The following symbols are used in this operating manual:
Warning
Safety instruction: Failure to observe this instruction can cause personal injury or damage the device.
Caution
Safety instruction: Failure to observe this instruction can damage the device.
Caution
Safety instruction relating to danger emanating from electrical currents or voltage: Failure to observe this instruction can cause personal injury or damage to the appliance and impair its functioning.
Note
Additional information on the operation of the device.
Action: This symbol indicates that action is required on your part. The required action is described step-by-step.
This symbol describes the result of an action.
fig. 2 1, page 3: this refers to an element in an illustration. In this case, "item 1 in figure 2 on page 3".
Please observe the following safety instructions.
2 Safety instructions
The manufacturer will not be held liable for claims for damage resulting from the following:
- Damage to the device resulting from mechanical influences and excess voltage
- Alterations to the device without express permission from the manufacturer
- Use for purposes other than those described in the operating manual
The following fundamental safety measures must be observed when using electrical devices to protect against
- Electric shock
- Fire hazards
Injury
2.1 General safety
- Check that the voltage specification on the type plate is the same as that of the power supply.
- Ensure that other objects cannot cause a short circuit at the contacts of the device.
- Ensure that the red and black terminals never come into contact.
- Lay all cables so that they cannot be tripped over or damaged.
- Never pull the plug out of the socket by the cable.
- Disconnect the device from the mains: - Before cleaning and maintenance - After use
Electronic devices are not toys.
-
Keep electrical appliances out of reach of children or infirm persons. Do not let them use the appliances without supervision.
-
Persons (including children) whose physical, sensory or mental capabilities or lack of experience and knowledge prevents them from using the appliance safely should not use this appliance without initial supervision or instruction by a responsible person.
-
The device may not be used if the device itself or the connection cable are visibly damaged.
- If the mains power line of this device is damaged, it must be replaced by the manufacturer, customer service or a similarly qualified person in order to prevent safety hazards.
- This device may only be repaired by qualified personnel. Inadequate repairs can cause considerable hazards (fig. 1, page 3). If your device needs to be repaired, contact the manufacturer's customer services.
2.2 Operating the device safely
- Caution - danger of fatal injury from electric shocks
Do not touch exposed cables with your bare hands. This especially applies to all cables in the AC mains circuit.
- If you are working on electrical systems, ensure that there is somebody close at hand who can help you in emergencies.
- To be able to disconnect the device quickly from the mains, the socket must be close to the device and be easily accessible.
- Before starting the device, ensure that the power supply line and the plug are dry.
- Please observe that even if the fuse has blown, parts of the device may still be conducting a voltage.
- Set up the appliance in a dry location where it is protected against splashing water.
- Protect the device against corrosive fumes and salty or moist air.
- Protect the device and the cable against rain and moisture.
- Ensure good ventilation (fig. 2, page 3).
- Keep a distance of at least 5cm clear on all sides of the charger. During operation, keep all objects that can be damaged by high temperatures away from the device.
-
Do not use the device in areas where flammable gases are present such as in the keel areas of petrol-driven boats or close to propane tanks.
-
Do not operate the device in systems with lead acid batteries. These batteries give off explosive hydrogen gas that can be ignited by sparks on electrical connections.
Always switch the device off after operation.
2.3 Safety precautions when handling batteries
- Caution!
Only use rechargeable batteries.
- Warning - danger of injuries
Batteries contain aggressive and caustic acids. Avoid battery fluid coming into contact with your body (fig. 3, page 3). If your skin does come into contact with battery fluid, wash the part of your body in question thoroughly with water.
- Warning - danger of explosions
Prevent any metal parts from falling on the battery. This can cause sparks or short-circuit the battery and other electrical parts.
- Warning - danger of explosions
Make sure the polarity is correct when connecting the battery: red terminal: positive battery terminal black terminal: negative battery terminal
- Wear goggles and protective clothing when you work on batteries. Do not touch your eyes when you are working on the battery.
- Ensure the device is standing firmly.
The device and the batteries must be set up in such a way that they cannot tip over or fall down. - Follow the instructions of the battery manufacturer and those of the manufacturer of the system or vehicle in which the battery is used.
-
Never attempt to charge frozen batteries (fig. 4, page 3).
-
Do not smoke and ensure that no sparks can arise in the vicinity of the battery (fig. 5, page 3).
- If you need to remove the battery, first disconnect the earth connection. Disconnect all connections and all consumers from the battery before removing it.
3 Scope of delivery
- Charger
- Operating manual
4 Intended use
The chargers WAECO PerfectCharge IU6 (item no. MBC-IU6), IU8 (item no. MBC-IU8) and IU12 (item no. MBC-IU12) can be used to charge the following types of battery:
- Lead starter batteries
- Lead gel batteries
- Maintenance-free batteries
Fleece batteries
with the capacities and voltages specified in the chapter "Technical data" on page 41.
Never use the devices to charge other battery types (such as NiCd or NiMH).
Warning - danger of explosions!
Batteries with a cell short circuit may not be charged. There is a danger of explosions due to oxyhydrogen gas.
Nickel-cadmium batteries and non-rechargeable batteries may not be charged with the charger. The sleeves of these batteries can burst in an explosive manner.
5 Technical description
5.1 Function
The battery charger is designed for 12V vehicle batteries.
A control function checks the voltage of the battery before charging begins. If the battery is already charged, the charger will not begin charging. This prevents the battery from becoming overcharged. The device will not charge deep-discharged batteries.
The charger has safety features that prevent the following:
- Short circuit
Overheating - Overloading
- Inverse polarity
The battery charger has an IU characteristic.
5.2 Displays and controls
The charger features the following displays and controls:
| No. in fig. 7, page 5 | Element | Explanation |
| 1 | Red “Error” LED | This LED lights up if the battery terminals are reversed. |
| 2 | Blue “Charging status” charging display | The charging display consists of three LEDs that show the charging status of the battery. The LEDs light up as the battery charges. When all three LEDs light up, the battery is fully charged. |
| 3 | “0/I” switch | Switches the charger on (“I) and off (“0”). |
5.3 Battery terminals and cables
The cables can be wrapped around the feet of the device for storage.
The battery terminals (fig. 8 1, page 5) and the mains plug (fig. 8 2, page 5) can be stored in the back of the device.
6 Using the charger
Warning - danger of explosions!
Batteries with a cell short circuit may not be charged. There is a danger of explosions due to oxyhydrogen gas.
Nickel-cadmium batteries and non-rechargeable batteries may not be charged with the charger. The sleeves of these batteries can burst in an explosive manner.
6.1 Connecting the charger
Caution - risk of damage
The charger must be installed in a place that is protected from moisture and humidity.
Make sure:
- No flammable materials or gases are in the vicinity.
- The installation location is well ventilated.
- The installation surface is flat and sufficiently firm.
Make sure the mains cable and connecting cables to the battery are not stretched, kinked or resting on sharp edges.
The air intake and outlet openings of the charger must be kept clear.
Disconnect the car battery from the vehicle electrics before charging to prevent consumers from affecting the charging process: Disconnect the negative terminal before the positive terminal.
Note
Please observe that all volatile memories of the comfort electronics will lose their stored data when the battery is disconnected.
You will have to re-enter the following data after reconnecting the fully charged battery:
Radio code
- Vehicle clock
- On-board computer, etc.
You can find instructions for making these settings in the corresponding operating manual.
Prepare the battery as follows if it is a non-maintenance-free battery:
Clean the surface of the battery using a damp cloth to prevent dirt from getting into the battery.
Unscrew the sealing caps from every battery cell where possible.
Warning - danger of acid burns
Avoid coming into contact with the battery fluid.
Check the level of the battery fluid.
If the fluid is below the minimum level in one or more cells, fill distilled water in up to the filling mark.
Never use normal tap water.
Leave the cells open during the charging process, so that any gases can escape.
Connecting the charger
Plug the power plug into an earthed and correctly fused 230V power socket.
Consult a specialist if you are uncertain.
Connect the red positive terminal of the charger to the positive terminal of the battery (designation +) (fig. 6 A, page 4).
Note
The positive terminal is not connected to the bodywork when it is connected.
Connect the black negative terminal of the charger to the negative terminal of the battery (designation -) (fig. 6 B, page 4).
Note
The negative terminal is connected to the bodywork when it is connected.
The charger is ready to charge the connected battery.
6.2 Charging the battery
The charger can charge non-maintenance-free and maintenance-free lead acid batteries (wet, gel and fleece types) with a rated voltage of 12V .
Warning - danger of explosions!
Do not use the device with batteries with other rated voltages.
Note
During the charging process you can interrupt the charging process at any time.
To charge the batteries, proceed as follows:
Connect the charger (chapter "Connecting the charger" on page 34).
Set the switch (fig. 7 3, page 5) to "I".
Caution - risk of damage
If the red LED (fig. 7 1, page 5) is lit, you have connected the battery terminals with reverse polarity.
Switch off the charger and correct the connections.
The automatic charging process starts.
The blue charging display (fig. 2, page 5) displays the current charging status of the battery.
The charging display consists of three LEDs that show the charging status of the battery:
| Display | Explanation | |
| lower LED flashes | the battery is almost empty | |
| The bottom and middle LEDs flash | the battery is approx. 50% charged | |
| All three LEDs flash | the battery is approx. 80% charged | |
| all three LEDs are lit | charging is roughly 90% complete IU6: the battery is fully charged If the charge current falls below 0.2 A, the device switches off (the LEDs go out). IU8, IU12: the battery is fully charged and the charger switches to conservation charging mode All three LEDs remain on. | |
Note
With the conservation charging function, the battery is constantly recharged to compensate for self-discharging.
Note
Observe the following special case:
The charger has a control function that checks the voltage of the battery before charging. If you connect a battery that is completely charged ( >13.2V ) or a deep-discharged battery, the charger will not switch on and the blue charging display remains off.
Switch off the charger.
Remove the terminals from the battery.
6.3 Disconnecting the charger
Caution - risk of damage
Do not cause a short circuit when disconnecting the charger.
Switch off the charger once charging is complete by setting the switch (fig. 7 3, page 5) to "0".
Disconnect the black negative terminal of the charger.
Disconnect the red positive terminal of the charger.
Unplug the 230 V power cable.
Warning - danger of acid burns
Avoid coming into contact with the battery fluid.
If the battery is a non-maintenance-free battery, you must also carry out the following two steps:
Check the fluid levels of the battery cells.
If the fluid is below the minimum level in one or more cells, fill distilled water in up to the filling mark.
Never use normal tap water.
Close the opened sealing caps on the battery cells.
Connect the battery
Grease the battery terminals with a little terminal grease to protect them from corrosion.
Reconnect the battery to the vehicle.
7 Troubleshooting
Note
If you have detailed questions on the battery specifications please contact the battery manufacturer.
The voltage of the battery does not increase after the charger has been connected and put into operation.
Use a suitable multimeter to check whether the voltage of the battery terminals increases during charging.
Check whether the terminals are connected properly to the battery terminals.
Clean the battery terminals.
The battery is not completely charged after charging for approximately 20 hours.
Disconnect the charger from the mains power.
Remove the charger terminals from the battery and wait for a few minutes.
Use a suitable multimeter to check the voltage of the battery terminals.
If the multimeter displays a voltage of 10V or below, this means that the battery is defective and can not be charged.
Have the battery checked by a specialist or dispose of the battery in a suitable manner.
The battery discharges itself after a short time if it is not used.
Use a suitable multimeter to check the voltage of the battery terminals.
If the multimeter displays a voltage below 12V , the battery is too weak to be able to remain charged.
Have the battery checked by a specialist or dispose of the battery.
8 Cleaning and maintenance
Caution - danger of electrocution
Always disconnect the device from the mains before you clean and service it.
Caution - danger of damaging the device
Never clean the appliance under running water or in dish water. Do not use abrasive cleaning agents or hard objects during cleaning as these can damage the device.
Occasionally clean the device with a damp cloth.
9 Guarantee
The statutory warranty period applies. If the product is defective, please contact the manufacturer's branch in your country (see the back of the instruction manual for the addresses) or your retailer. For repairs and warranty claims, you must submit the following documents:
A copy of the receipt with purchasing date
- Reason for the claim or a description of the fault
10 Disposal
If possible, always take the packaging material for recycling.
If you wish to finally dispose of the device, ask your local recycling centre or specialist dealer for details about how to do this in accordance with the applicable disposal regulations.
Protect the environment!
Do not dispose of defective batteries in general household waste. Return defective rechargeable batteries/conventional batteries to your retailer or take them to a collection point.
11 Technical data
| IU6 | IU8 | IU12 | |
| Item number | MBC-IU6 | MBC-IU8 | MBC-IU12 |
| Input voltage range: | 207 – 253 V ~ | ||
| Maximum input current: | 1 A | 1.5 A | 2 A |
| Efficiency: | Up to 80% | Up to 85% | Up to 85% |
| Power consumption when not charging: | 6 W | 10 W | 10 W |
| Rated battery voltage: | 12 V = | ||
| Retention voltage: | - | 13,6 V = | 13.6 V = |
| Rated charging current: | 6 A | 8 A | 12 A |
| Charging characteristics: | IU Automatik | ||
| Maximum ambient temperature: | 0 °C – 40 °C | ||
| Maximum battery capacity: | approx. 60 Ah | approx. 80 Ah | approx. 120 Ah |
| Dimensions (W x H x D): | 155 x 148 x 198 mm | 155 x 148 x 228 mm | 155 x 148 x 228 mm |
| Weight: | Approx. 1.5 kg | Approx. 1.9 kg | Approx. 1.9 kg |
| EAN code: | 4015704169218 | 4015704169225 | 4015704169232 |
Versions, technical modifications and delivery options reserved.
12 Hints on handling batteries
12.1 What you should know about batteries
A battery is an energy storage device with limited capacity. The difference to electricity from a mains socket: the energy removed from the battery must be replaced 100% . If this is not the case, the battery has a "negative charge balance". This causes a loss of capacity, which in turn causes the battery to fail.
Starter batteries and supply batteries are designed for different tasks: Starter batteries have to supply a large amount of electricity to start the engine, and then function as energy buffers with small partial cycles. Supply batteries or on-board batteries are discharged and charged through small currents over longer periods of time, which means that they are subject to far heavier loads. This is why an ideal charging technique is especially important.
The capacity used should always be replaced by prompt and complete charging.
During a journey, the light system is usually the only tool available for recharging the supply battery. The light system and solar panel are, however, only supporting charging devices. Complete recharging is only possible using a suitable charger connected to an external 230 V mains power socket.
Gel and fleece type batteries should be charged using a charger with IU0U designation.
12.2 Choosing the correct battery
Consider the following: There is no battery that supplies unlimited energy.
Draw up an energy balance sheet for all consumers in the vehicle. This enables you to check how much energy is used every day, and therefore how much energy must be replaced to the battery.
Example of an energy balance:
| Overview of the main consumers | |
| Consumer | Power |
| Lighting | 150 W |
| Radiator fan | 120 W |
| Interior fan | 100 W |
| Windscreen wipers | 70 W |
| Radio with CD changer | 60 W |
| Cigarette lighter | 50 W |
| Brake light | 40 W |
| Hot water centre | 800 W |
| Coffee maker | 200 W |
| Vacuum cleaner | 175 W |
| Car hair dryer | 175 W |
| Car kettle | 125 W |
| Absorber cooler | 100 W |
| Absorber refrigerator | 100 W |
| Cooler | 75 W |
| Colour television | 75 W |
| Refrigerator | 45 W |
| Extractor fan | 30 W |
| A/C system | 23 – 36 W |
| Digital receiver | 11 W |
| Immersion pump | 10 – 35 W |
| Reversing video system, monitor | 8.4 W |
| Combination alarm unit | 1.2 W |
The capacity required for a cooler can be calculated as follows:
Power / voltage 75 W/12 V
= amperage = 6.25 A
x average use per day in hours (h) 8 h
= required capacity in amp hours = 50 Ah
You can use this method to determine the entire capacity of all electrical consumers in the vehicle. You will find the power specifications in Watts on type plates, lamp sockets, etc.
Multiply the resulting Ah value by a safety factor of 1.5, and the result is the capacity that the battery requires. If your vehicle electrics are not supplied with enough power, you can use an additional supply battery, e.g. in caravans, boats, etc..
12.3 Charging the batteries properly
If you are using the vehicle for recreational or sports purposes, you should observe the following recommendations:
Always begin your journey with a fully-charged battery.
- Recharge the battery using the installed on-board charger at every chance during your trip.
- Once the journey is over, charge the battery for more than twelve hours using the on-board charger, as the battery is usually not fully charged even during longer mobile use (return journey).
- If it is not to be used for a long period of time, e.g. during the winter break, the battery must also be charged fully for more than twelve hours. Disconnect the positive terminal afterwards.
Note
Bad chargers are the main cause for insufficient power supply to the on-board electronics. Proper on-board chargers work according to the IU0U specifications. These devices are available from your specialist dealer (www.waeco.com).
Note
The required charger strength depends on the battery capacity. The rule of thumb is: 10% of the battery capacity in Ah/h is the minimum charging power of the charger.
For example, a 15 A device is suitable for battery capacities between 40 and 150 Ah.
12.4 Avoiding battery failure
Batteries can fail because they are not charged properly (negative charging balance) or deep-discharged.
Failure due to negative charging balance
A negative charging balance can be caused by the following:
- Insufficient charging by the lighting system due to undervoltage (loss of voltage in the on-board electrics or defective and/or incorrectly set voltage regulator)
- Negative energy balance because too many electrical consumers are used (the journey is too short for the alternator to recharge the battery completely)
Failure due to deep discharge
Deep discharge can be caused by the following:
- Consumer are not switched off
- Self-discharge if the vehicle is not used for a long time (independent of constant electric consumers)
Loss of power due to self-discharge depends on the battery. However, self-discharging increases noticeably (by up to seven times) as the temperature increases.
In the summer, this increased self-discharging due to increased temperature, combined with constant consumers, can quickly cause a deep discharge if the battery is not recharged using the on-board device.
How to avoid deep discharge (during longer periods of disuse)
Always switch off consumers that are not in use.
- Take silent consumers into account when calculating your energy requirements.
Note
Recharge batteries once a month to balance out power loss caused by self-discharging.
Load batteries for at least 48 hours after deep discharge.
Checklist of causes for battery failure
In many cases, the failure of the on-board electronics are due to causes that you can determine and rectify yourself. In the event of problems, please check the following:
- Charging voltage on the battery terminals too low (under 14.1 V)
Defective lighting system - Charging voltage too high (above 14.4V ) due to defective voltage regulator (if the charging voltage is too high, this destroys the battery)
- Loose v-belt
- Oxidised or loose connection terminals
- Defective switching relay on an electrical consumer
- Short circuit in the on-board electronics
- Leakage currents in the on-board electronics
Note
Check the state of the battery by measuring the no-load voltage (see table below).
Only measure this voltage at least 24 hours after the battery was last charged. Do not use the battery between charging and measuring.
| No-load voltage in V | >12.8 | 12.55 | 12.3 | 12.2 | < 12.0 |
| Charging condition in % | 100 | 75 | 50 | 25 | 0 |
IU6, IU8, IU12
5 Description technique
5.1 Fonction
- startaccu's (loodaccu's)
- lood-gel-accu's
- onderhoudsvrije accu's
vliessaccu's
Overseas + Middle East
WAECO Pacific Pty. Ltd.
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www.waeco.com
