ChargeXpress
Contents
1. 10 Multi function ON OFF buttons Charger is OFF Press Multi function ON OFF button for more then 2 seconds This switches on the charger When the charger is switched on a corresponding LED blinks indicating the user to select a battery technology Press the button consequently to scroll through the list with battery technologies When the button is no longer pressed the charger automatically accepts the selection Charger is now ready to charge a battery Charger is ON Press Multi function ON OFF button short This stops the charge cycle if active When Multi function ON OFF button is pressed for more then 2 seconds the charger switches completely off Charger ON Charger OFF Button pressed short Stop charge cycle Button pressed long Switch on charger Button pressed long Switch off charger Status LED s Located at the bottom of the charger are two multi coloured LEDS Each charger channel has one LED assigned When the charger is switched on a self test is performed If something is not according to specification the multi coloured LED will turn RED Possible colours Green o Indicates charger is OK o Continuous fully charged battery Red o Solid Red LED Charger internals are not OK See trouble shooting section o Blinking RED LED Blink rate indicates a fault Count the blink rate and check trouble shooting section for more details Orange o Solid lit LED indicates that battery is being c2. MIDTRONICS Battery Management Innovation ChargeXpress PRO 15 PRO 25 PRO 25 2 INSTRUCTION MANUAL TABLE OF CONTENT TABLEOFCONTEN Tita a A A is 3 PRECAUTIONS cuanta A A A A dat 4 SAFETY INSTRUCTIONS ucraniana ada iaa 5 SPEGIFICA TIO Sit AA a ota 9 GENERAL A AE SIP 9 INPUST RATINGS ta A E id 9 QUTPUT RATING Sis oitaar ni eoliano cad E 9 GETTING STARTED esac eae ee Aa A Aa O ea ee dad 9 FITTING INSTALEATIONS 20 tit A A ete aed AA deat 9 OPERATION lt lt dd A a setae ad 10 VISUAL NSRECGTON naaa a a a a depart 10 FRONTPANEL cuina aaa 10 Multi function ON OFF DU LONS occccoccnncnccnccnnnncnoncncncnoncnnnonononononononnnnonrnnnnnoncnnnnnoninnnnnenenennns 11 Status LEDS sie sc dica A A A dao ito 11 FUNCION ED tias 11 CHARGE SEQUENCE 000 ln caida a A a 12 POWER SUPRLVO MODE 23 ate A A a AE 12 CHARGEXPRESS PRO OPERATING STEPS 00ooocccccncnccccnocnccnncnnncnnonoconononononnnrnnnononcnonnnonnrnnenancnnonarinns 13 IMPORTANT NOTES criada rat rss 13 1 CONNECT CHARGEXPRESS PRO TO BATTERY c oooccccnnncnnncnnnccnncnnnononncnnonononnnnnnnnononos 13 2 CONNECT TO POWER A Cherita ei aE a E AN A NNE s 13 3 SELECT CHARGEXPRESS PRO MODES 00occcccconcnnnncnocnnnnnncononnoncnnnnnononnnnnoninenoninonenonons 13 CHARGEXPRESS PRO FUNCTIONS cccccccscccscccscssccseteccssssnscscteccunessscudeenceuucdessseesecuacutedsessecuacesedueseecs 13 TROUBLE SHOOTIN Goiania dada 14 OPERATION arras 14 ERROR O ODE k S iuunustasaidabr
3. aiii adan adas 14 WARRANTY onain a ATA aaa a traca 15 PRECAUTIONS Always use the following precautions when working with batteries DANGER POISON SHIELD EYES EXPLOSIVE GASES CAN CAUSE BLINDNESS OR INJURY NO SPARKS y NO FLAMES SULFURIC ACID CAN CAUSE E BLINDNESS OR SEVERE BURNS SAFETY INSTRUCTIONS IMPORTANT READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL KEEP IT WITH OR NEAR CHARGEXPRESS PRO ALL TIMES IMPORTATN SAFETY INSTRUCTION 1 WORKING IN THE VICINITY OF A BATTERY CAN BE DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION AND WHEN DISCHARGED OR CHARGED FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGEXPRESS PRO YOU RE READ THIS MANUAL AND MAKE CERTAIN YOU FULLY UNDERSTAND IT AND FOLLOW THE SAFETY AND OPERATING INSTRUCTIONS EXACTLY 2 To reduce risk of battery explosion follow these safety instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery Review cautionary marking on these products and on engine and on vehicle or equipment containing the battery 3 CAUTION To reduce the risk of injury charge only rechargeable LEAD ACID TYPE batteries which may include MAINTENANCE FREE LOW MAINTENANCE AGM SPIRAL GEL or DEEP CYCLE batteries Other types of batteries may burst causing personal injury and damage NEVER RECHARGE NON RECHARGEABL
4. and disconnect battery leads only when AC supply cord is disconnected 15 When charging a battery locate in a dry well ventilated area 16 Never place articles on or around CHARGEXPRESS PRO or locate CHARGEXPRESS PRO ina way that will restrict the flow of cooling air through cabinet 17 An extension cord should not be used unless absolutely necessary 18 Have damaged cord or plug replaced immediately only by a qualified service center to prevent risk of electric shock or fire 19 Do not expose CHARGEXPRESS PRO to wet weather conditions PERSONAL PRECAUTIONS Always have someone within range of your voice or close enough to come to your aid when working around batteries Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection clothing protection and wear rubber soled shoes Place damp cloth over battery to protect against acid spray When ground is very wet or covered with snow wear rubber boots Avoid touching eyes while working near battery If battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immediately flush with running cold water for at least 10 minutes and get doctor s attention NEVER smoke or allow a spark or flame in vicinity of battery or engine Be extra cautious to reduce risk of dropping a metal tool onto battery It might spark or short circuit the battery or other electrical part that may cause an exp
5. is completely inserted into the AC outlet b Make sure the AC outlet is live check fuse or circuit breaker c Check the AC power cord for damage d Check the fuses on the outside of the charger ERROR CODES Through the red STATUS LED s error codes can be transmitted the selected green function LED will blink at the same with the same frequency Error code Description Action 01 Reverse polarity Correct clamps red to plus and black to minus pole 02 Connection problem Correct connection and restart charge sequence 03 Non 12V battery connected Connect correctly to 12 V 04 Battery voltage too low lt 5 5 V Battery deeply discharged consider replacement battery might be damaged 05 Charge voltage problem no Consider battery replacement increase 06 Charge current problem no Battery replacement recommended increase 07 Too low charge current Battery replacement recommended 08 Internal current failure Switch off unit press ON OFF button for 2 seconds and try again If problem is consistent 09 Internal voltage failure call for service 10 Internal charger temperature too Switch off unit press ON OFF button for 2 high seconds Switch on again and leave the fan running If fan is not running call for service The charger will display any error in the charger as a blink code The blink rate is oe Sample this blink rate means error code 3 non 12V battery connected FUSES On the
6. outside of the charger you find 2 fuses 14 WARRANTY This battery charger is warranted to be free of defects in materials and workmanship for a period of two 2 years from date of purchase Midtronics will at our option repair the unit or replace the unit with a remanufactured charger This limited warranty applies only to Midtronics battery charger and does not cover any other equipment wear and tear parts such as the cable static damage water damage over voltage dropping the unit or damage resulting from extraneous causes including owner misuse Midtronics is not liable for any incidental or consequential damages for breach of this warranty The warranty is void if owner attempts to disassemble the unit or to modify the cable assembly 15 Midtronics Inc Corporate Headquarters 7000 Monroe Street Willowbrook IL 60527 USA Phone 1 630 323 2800 Toll Free 1 800 776 1995 Fax 1 630 323 2844 E Mail net2 midtronics com ISO 9001 2000 Certified ISO 14001 2004 Certified Canadian Inquiries Toll Free 1 866 592 8053 Fax 1 630 323 7752 E Mail canada midtronics com 168 953A EN 12 06 MIDTRONICS Battery Management Innovation www midtronics com Midtronics b v European Headquarters Serving Europe Africa the Middle East Lage Dijk Noord 6 3401 VA IJsselstein The Netherlands Phone 31 306 868 150 Fax 31 306 868 158 E Mail info europe midtronics com ISO 9001 2000 Certified European Sales Locatio
7. E BATTERIES 4 Ifyou are uncertain as to the type of battery you are attempting to charge or the correct procedure for checking the battery s state of charge contact the seller or battery manufacturer 5 Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire electric shock or injury to persons 6 To reduce risk of damage to electric plug and cord pull by plug rather than cord when disconnecting CHARGEXPRESS PRO 7 Position AC and DC leads to avoid tripping over them and to prevent damage by hood doors or moving engine parts protect from heat oil and sharp edges 8 Do not operate CHARGEXPRESS PRO if it has received a sharp blow been dropped or otherwise damaged in any way take it to a qualified service center 9 Do not disassemble CHARGEXPRESS PRO take it to a qualified service center when repair is required Incorrect reassembly may result in a risk of electric shock or fire 10 If the CHARGEXPRESS PRO is in need of service call Midtronics at 31 30 6868 150 11 To reduce risk of electric shock unplug CHARGEXPRESS PRO from the AC outlet before attempting any maintenance or cleaning Turning off the controls only will not reduce this risk 12 BOAT BATTERIES MUST BE REMOVED AND CHARGED ON SHORE TO SAFELY CHARGE THEM ON BOARD REQUIRES EQUIPMENT ESPECIALLY DESIGNED AND UL CE LISTED FOR MARINE USE 13 Do not overcharge battery See Safety Instructions 3 14 Connect
8. GS 230 V AC 16A 50 60Hz OUTPUT RATINGS Charger DC Voltage Amps Watts PRO 15 12V 15A 180 PRO 25 12V 25A 300 PRO 25 2 12V 2X25A 300 GETTING STARTED Before connecting the unit to the mains please connect the charge cables to the unit Cable 1 goes into position 1 cable 2 goes into position 2 PRO 25 2 only Make sure the cables are connected nice and tidy under the strain relieve shown in position 3 using the bracket with the wing nut Plug in the main lead at position 4 Charge cable nr 1 Charge cable nr 2 PRO 25 2 only Strain relieve AC power cable PON gt FITTING INSTALLATIONS The charger can be mounted vertically or horizontally while maintaining a free area of 15 cm 6 all around This allows an optimal cooling with air circulation Two screw holes 170 mm apart with a 4 mm diameter are provided for mounting the charger As mounting positions think of vehicle lifts wall and or tool trolleys OPERATION VISUAL INSPECTION Visually inspect the battery before charging If there are any signs of a leaking or cracked case discard the battery Do not attempt to charge a battery that is in this condition FRONT PANEL MIDTRONICS MIDTRONICS MIDTRONICS ChargeXpress ChargeXpress ChargeXpress PRO 25 2 pa O O mm 0 A A as em 0 1 Oo B O 0 4 0 oe Function selection LED s 2 Multi Function ON OFF buttons 3 Status LED s
9. OFF disconnect AC cord remove clamp from vehicle chassis and then remove clamp from battery terminal For positive grounded vehicle connect NEGATIVE BLACK clamp from charger to NEGATIVE ungrounded post of battery Then connect POSITIVE RED clamp to vehicle chassis or engine block away from battery Do not connect clamp to carburetor fuel lines or sheet metal body parts Connect to a heavy gauge metal part of frame or engine block When disconnecting charger turn switches OFF disconnect AC cord remove clamp from vehicle chassis and then remove clamp from battery terminal CHARGEXPRESS PRO CONNECTION BATTERY NOT IN VEHICLE If necessary to remove battery from vehicle or equipment always remove grounded terminal from battery first WARNING Make sure all vehicle loads are OFF to prevent a possible arc FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE A SPARK NEAR BATTERY MAY CAUSE AN EXPLOSION TO REDUCE RISK 1 Check polarity of battery posts POSITIVE post usually has larger diameter than NEGATIVE post 2 Connect POSITIVE RED CHARGEXPRESS PRO clamp to POSITIVE post of battery 3 Connect NEGATIVE BLACK CHARGEXPRESS PRO clamp to NEGATIVE post of battery SPECIFICATIONS GENERAL Lead acid batteries GEL AGM SPIRAL Flooded Power supply Memory Save Number of cells 6 Rated capacity 20 to 250Ah Note A 24 V operation consists of two 12 V 6cell batteries connected in series INPUT RATIN
10. harged Function LED Each charger channel has 4 LEDS to indicate the selected function A blinking LED indicates a fault see therefore the code table 11 CHARGE SEQUENCE To switch ON the unit press and hold down one of the Multi function ON OFF buttons for more then two seconds The unit will perform a self test and the green STATUS LED s will light up to indicate charger is ready and OK In case of a problem the red LED will be lit This red LED is also used to indicate any error code in the charger The LED will blink at a certain rate Select a battery technology to ensure that the battery is properly charged To select any of the 4 positions press the Multi function ON OFF button shortly The top LED lead acid starts blinking Pushing the Multi function ON OFF button again within 4 seconds will scroll to the next selection This can be continued until the proper selection is made When the button is no longer pressed the LED will turn solid green indicating that that selection is activated With the charger clamps connected to a battery the LED will turn to solid orange and starts charging The Multi function ON OFF button can be pressed at any time during a charge cycle to stop the charger Position 1 Lead Acid charge curve 2 AGM ESPIRAL charge curve 3 GEL charge curve POWER SUPPLY MODE Integrated in the charger is also a Power Supply function This mode ensured that the battery is kept fully charged during programmi
11. ing soda and water Clamps must be cleaned after every use 1 CONNECT CHARGEXPRESS PRO TO BATTERY Connect the CHARGEXPRESS PRO charging clamps to the battery in accordance with all precautions and safety instructions IF YOU ACCIDENTALLY REVERSE THE CLAMP CONNECTIONS THE CHARGEXPRESS PRO WILL INDICATE THIS WITH A RED LED AND BLINK RATE 01 SWITCH CHARGER OFF BEFORE CHANGING CLAMPS 2 CONNECT TO POWER AC Plug the CHARGEXPRESS PRO into a dedicated grounded 16 Amp AC outlet Do not use an AC line cord adapter or extension cord Switch on the charger 3 SELECT CHARGEXPRESS PRO MODES Use the Multi Function ON OFF button to activate charger and selecting the battery technology used for charging the battery Lead acid AGM SPIRAL GEL Power supply or Memory Saver After selecting one of the modes the charger will start charging automatically This is indicated by the Orange LED CHARGEXPRESS PRO FUNCTIONS To charge the different battery technologies the CHARGEXPRESS PRO has got a button to select one of the following Battery technology U Boost U Float Flooded Lead acid Calcium Antimony 16 50 14 20 Pulse 13 5 14 8 AGM SPIRAL 16 50 14 40 Pulse 13 5 14 8 GEL 16 50 14 30 Pulse 13 5 14 8 Power Supply Memory Saver N a 13 10 13 TROUBLE SHOOTING OPERATION The Multi Function ON OFF button is pressed but the CHARGEXPRESS PRO does not power up a Make sure the AC power cord
12. losion Before working with a battery remove personal metal items such as rings bracelets necklaces watches etc A battery can produce a short circuit current high enough to weld such items causing a severe burn Use charger for charging LEAD ACID batteries only The CHARGEXPRESS PRO is not intended to supply power to a low voltage electrical system other than applications using rechargeable type batteries Do not use battery charger for charging dry cell batteries commonly used with home appliances These batteries may burst and cause personal injury and property damage NEVER charge a frozen battery thaw it out first Charging will then be safer and more efficient PREPARING THE BATTERY If necessary to remove battery from vehicle to charge always remove grounded terminal from battery first Make sure all accessories in the vehicle are off so as not to cause an arc Use stud adapters on side post and or Truck batteries that are not in the vehicle Be sure area around battery is well ventilated while battery is being charged Using a piece of cardboard or other nonmetallic material as a fan can forcefully blow gas away Clean battery terminals Be careful to keep corrosion from coming into contact with your eyes Add distilled water in each cell until battery acid reaches level specified by manufacturer This helps purge excessive gas from cells Do not overfill For a battery without caps carefully follow the manufacturer s recharging in
13. ng of ECU s or regular vehicle maintenance When the charger is not yet switched on press and hold down one of the Multi function ON OFF buttons for more then two seconds The unit will perform a self test and the green STATUS LED s will light up to indicate charger is ready and OK In case of a problem the red LED will be lit This red LED is also used to indicate any error code in the charger The LED will blink at a certain rate To select the Power Supply Mode press the Multi function ON OFF button shortly until position 4 is reached The LED will now turn to solid green With the charger clamps connected to a battery the LED will turn to solid orange to indicate that it is in progress Any consumer in the vehicle that needs current will get this from the charger Only then when current is needed in the vehicle the charger will provide this in any other situation no current flows Position 4 Power Supply Mode 12 CHARGEXPRESS PRO OPERATING STEPS IMPORTANT NOTES Clean the battery terminals If stud adapters are required fasten them with the proper tool Do not use the battery clamps to tighten adapters Use stud adapters on Side Post and or Truck batteries that are not in the vehicle Never remove the clamps from a battery to abort an active charging session Always push the Multi function ON OFF button shortly before removing the clamps Do not leave clamps lying in battery acid Clean up any acid spills immediately e g with bak
14. ns IJsselstein The Netherlands Paris France D sseldorf Germany Midtronics Inc 16 Midtronics China Office China Operations Room 16E 1 Nobel Center No 1006 3rd Fuzhong Road Shenzhen China 518026 Tel 86 755 82990389 Fax 86 755 82990399 E Mail chinalnfo midtronics com Asia Pacific excluding China Contact Corporate Headquarters at 1 630 323 2800 or E Mail asiapacinfo midtronics com
15. r size and shape as those of plug on CHARGEXPRESS PRO b Extension cord is properly wired and in good electrical condition and c Wire size is large enough for AC ampere rating of CHARGEXPRESS PRO CHARGEXPRESS PRO CONNECTION BATTERY IN VEHICLE Before working on vehicle firmly apply emergency brake and place gearshift to NEUTRAL shift an automatic transmission to P Locate CHARGEXPRESS PRO as far away from battery as CHARGEXPRESS PRO cords permit and position AC and DC cords to avoid stepping on or tripping over them and to prevent damage by hood doors or moving engine parts Stay clear of fan blades belts pulleys and any other parts that can cause physical injury Turn OFF all vehicle loads including door lights and correct any defects in car s electrical system that may have caused low battery Check polarity of battery posts The POSITIVE post usually has larger diameter than NEGATIVE post Determine which post of battery is grounded connected to chassis If negative post is grounded see step 7 If positive post is grounded see step 8 For negative grounded vehicle first connect POSITIVE red clamp from CHARGEXPRESS PRO to POSITIVE ungrounded post of battery Then connect NEGATIVE BLACK clamp to NEGATIVE post of battery Do not connect clamp to carburetor fuel lines or sheet metal body parts Connect to a heavy gauge metal part of frame or engine block When disconnecting charger turn switches
16. structions Study all battery manufacturers specific precautions such as removing or not removing cell caps while charging and recommended rates of charge Determine the voltage of the battery and make sure that the output voltage menu selection is set at the correct voltage DC CONNECTION PRECAUTIONS 1 Set the CHARGEXPRESS PRO switch in the OFF position and AC cord should be DISCONNECTED from electrical outlet before you connect and disconnect CHARGEXPRESS PRO clamps Never allow clamps to touch each other When attaching CHARGEXPRESS PRO clamps be certain to make the best possible mechanical as well as electrical connection Clamps should be kept clean AC POWER CORD CONNECTION INSTRUCTIONS 1 CHARGEXPRESS PRO should be grounded to reduce risk of electric shock CHARGEXPRESS PRO is equipped with an electric cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances DANGER NEVER ALTER AC CORD OR PLUG PROVIDED IF IT WILL NOT FIT OUTLET HAVE PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN IMPROPER CONNECTION CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK An extension cord should not be used unless absolutely necessary Use of improper extension cord could result in a risk of fire and electric shock If extension cord must be used make sure that a Pins on extension cord are the same numbe
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