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This Hella Battery Charger (7116) is
designed to charge light, medium and
heavy duty batteries of the type used in
boats, trucks, tractors and most other
types of farm and industrial equipment.
Before using this charger, it is essential
that you read the following information.
CONTROL PANEL
1. Normal/ Boost Start switch.
2. Hi/ Lo charge switch.
3. Regular/ Deep Cycle switch.
4. On/ Off switch.
5. Red ‘Standby’ indicator.
6. Yellow ‘Charging in progress’ indicator.
7. Green ‘Charging complete’ indicator.
NORMAL CHARGING
The output leads are fitted with
battery clamps and coloured for easy
identification of polarity. Red for positive
(+) and black for negative (-).
1. Before connecting or disconnecting the
charger to a battery, ensure that the
power point is switched ‘OFF’.
2. Ideally, disconnect the battery and
remove from the vehicle before
charging. If this is not possible,
disconnect the battery leads to
protect the electronic systems within
the vehicle. Also refer to any special
instructions in the vehicle owner’s
manual.
3. Remove the battery filler caps and
check the level of the electrolyte in
the cells. If necessary, top up with
distilled water so that the electrolyte is
6mm above the top of the plates (also
refer to ‘Low Maintenance Batteries’
section). Do not replace the filler caps
until the charging programme has been
completed.
4. Connect the clamps to the battery
terminals making sure that they bite
firmly and that polarity is correct.
5. Select ‘Regular’ or ‘Deep Cycle’ on the
Regular/ Deep Cycle selector switch for
the type of battery to be charged.
6. Select ‘Normal’ on the Normal/ Boost-
Start switch.
7. Select ‘Hi’ or ‘Lo’ on the Hi/ Lo selector
switch according to requirements (refer
to charging rates on page 4).
8. Only after connecting, switch on
the main supply to the charger. A
discharged battery in good condition
will automatically begin charging within
5 seconds. The red ‘Standby’ indicator
will dim and the yellow ‘Charging in
progress’ indicator will illuminate. The
charger will remain in this mode until
the battery is fully charged. The yellow
indicator and the green ‘Charging
complete’ indicator will illuminate
alternatively, showing that the battery
is being maintained in a fully charged
(float) condition.
9. After charging, switch off the mains
supply. Then remove the clamps from
the battery.
AUTOMATIC OPERATION
This battery charger incorporates
electronic sensing which automatically
initiates charging when the charge held by
the battery is below a satisfactory level.
It will charge constantly until the battery
attains full charge and then continue to
intermittently charge (pulse) when the
battery voltage falls below the optimum
level, thus always maintaining the battery
at full charge.
DEEP CYCLE BATTERIES
This battery charger is able to charge
regular or special ‘Deep Cycle’ type
batteries. These type batteries have a
lower charged voltage level (float voltage)
than regular batteries.
BOOST CHARGING
Boost charging is used to rapidly charge a
battery, usually prior to attempting to start
the engine in a flat battery situation.
Boost charging should be avoided on
small & deep cycle batteries. Do not
overcharge in the boost charge position –
recommended charge period is 5 minutes,
followed by a rest period of 15 minutes
before further charging. Do not leave the
charger unattended during boost charge.
NOTE: The Hi/ Lo switch is bypassed
when Boost/ Start is selected.
ENGINE STARTING
This charger, together with the vehicle’s
own flat battery, can deliver starting
currents in excess of 100 Amps for several
seconds, long enough to crank and start
the engine.
It is necessary to charge the battery for
a few minutes, using the Boost-charge
setting, before attempting to start the
engine. The benefit of this brief charge is
firstly that, when starting is attempted, all
the current from the charger goes to the
starter and not to the battery, and secondly
that this brief period of charging will enable
the battery to contribute to the starting
current.
Method
Make sure that all loads on the battery
are switched off and always observe the
correct polarity of connections, red to
positive (+), and black to negative (-).
Connect the ground connection to the
engine or chassis away from fuel lines
and battery vents.
1. Switch to ‘Boost/ Start’, turn the main
supply on, and allow the battery to
charge until the green and yellow
indicators begin to flash alternatively.
Do not leave in the Boost/ Start
mode for longer than 15 minutes
(refer to ‘Boost Charging’ section for
instructions).
2. Operate the starter with the charger
still on ‘Boost/ Start’. The engine
should start or briskly crank for several
seconds before the charger’s internal
cut-out operates.
3. If the engine cranks, the charger’s
internal cut-out comes into operation.
If the engine does not start after two or
three attempts, wait for a further period
of at least 5 minutes with the charger
on ‘Boost/ Start’ charge, and try again.
Note: If the starter operates well but
the engine does not start, identify the
reason and correct the fault (check fuel
and ignition).
4. If the engine does not crank, and after
a few seconds the charger’s internal
cut-out comes into operation, then this
is an indication that either the initial
charging period of the battery was not
long enough (allow a further period of
Boost-charge), the battery is very faulty,
the connections between the battery
and the battery connectors are faulty, or
that the starter motor is jammed.
5. If the engine does not crank, and the
charger’s internal cut-out does not
operate within a few seconds, then this
is an indication of a fault in the starting
system of the car. Check for a faulty
starter motor, solenoid, earth strap from
battery to car bodywork, earth strap
from engine to car.
OVERLOAD PROTECTION
The automatic feature of the charger
prevents batteries from being damaged
by overcharging and provides protection
for the charger against short-circuits and
reversed polarity connections.
There is a self-resetting thermal overload
in the input circuit and a self-resetting
overload in the output circuit.
Prolonged operation in excess of the
maximum ratings may cause the over-
loads to operate, switching the charger
output off. If this occurs, switch off the
charger and allow it to cool. The overload
will automatically reset and allow charging
to continue. However, if the thermal
overload repeatedly operates, it is possible
that the battery is faulty and should be
checked with a hydrometer and/ or Hella
Battery Tester, Part No. 7100.
The charger is also provided with fuse
protection in the input circuit, which will not
blow in normal operation. If the fuse blows,
replace only with a fuse of identical type
and rating.
Repeated fuse blowing indicates a
possible fault in the charger. In these
circumstances, you should contact an
authorised service agent.
CHARGING RATE (HI/LO)
The recommended charging rate for most
batteries is 100% of rated capacity. This
means that a 50 amp-hour battery would
normally be charged at 10 Amps for
10 hours.
Occasionally it may be necessary to charge
at a higher current in order to reduce
the charging time. A rough guide can be
calculated by dividing the rated capacity of
the battery by the continuous current rating
of the charger, e.g. a 60 amp-hour battery
requires 6 hours at 10 Amps.
BANK CHARGING
Several batteries may be charged
simultaneously by connecting each of them
in parallel with the charger, using separate
jumper leads for the purpose.
Charging time can be calculated by adding
the individual capacities of the batteries
in the bank and dividing this sum by the
continuous current rating of the charger.
Hi/ Lo setting may be used according
to requirements.
LOW MAINTENANCE
BATTERIES
The characteristics of low maintenance
batteries are somewhat different from
those of ordinary lead-acid batteries.
When fully charged, the low maintenance
battery does not gas as noticeably as
ordinary batteries. Nevertheless, the
usual safety precautions should still be
observed.
SAFETY INFORMATION
WARNING
Working in the vicinity of a lead-acid
battery is dangerous due to the emission
of explosive gases. These explosive gases
can be ignited by a spark, cigarette or
naked flame such as a cigarette lighter or
matches.
• Keep sparks and naked flames away
from battery at all times.
• Never smoke or light a cigarette near
a battery.
• Take extreme care with metal objects
and tools including items of jewellery
such as rings and watch bands. Metal
objects touching the battery terminals
may cause sparks or serious heat
burns to the user or wearer.
• Do not allow tools to drop on the
battery and never temporarily place
tools on top of a battery.
• When testing or working on or around a
lead-acid battery it is advisable to wear
protective eye glasses.
• When testing or charging a lead-acid
battery, ensure that the area you are
working in has plenty ventilation. Never
test or charge a battery in a confined
area.
• Do not use the charger in rain
or expose it to water from hoses or
sprinklers.
Lead-acid batteries contain Sulphuric Acid.
