KULON 100 chargers user manual

Kulon Series Charger – KULON 100

General instructions

The Kulon-100 charger is designed for charging 12-volt starter batteries with a capacity of 20 ... 95 Ah used in cars, motorcycles, boats, etc. It can also be used to power low-voltage auxiliary electronic and electrical equipment with supply parameters that correspond to the technical data specified below. Before operation, it is necessary to study this manual, the rules for the care and operation of batteries (should be supplied with the batteries), and the manuals for low-voltage devices that are planned to be connected to the Kulon-100.

Technical data

Mains voltage, 50 Hz, V . . . . . . . . . . . . . . . . . . . . . . . 220 ± 10%
No-load voltage, V . . . . . . . . . . . . . . . . . . . . . . . . . 14.8 ± 0.2
Output current, A
at voltage 0 ... 14.0 V . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.5
at voltage 14.0 ... 14.5 V . . . . . . . . . . . . . . . . . . . . 2.5 ± 0.5
at voltage above 14.5 V . . . . . . . . . . . . . . . . . . . . . not more than 0.2
Power consumption, W . . . . . . . . . . . . . . . . . . . . . not more than 100
Maximum power consumption without load, W . . . . . . . . not more than 4.0
Battery discharge current when power supply is off, mA . . not more than 10
Short-circuit current, A . . . . . . . . . . . . . . . . . . . . . . 6.0 ± 1.0
Weight, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50
Dimensions, mm . . . . . . . . . . . . . . . . . . . . . . . . . 160 x 84 x 60

The charger is designed for operation in moderate climate conditions at an ambient temperature from -5 °C to +40 °C and relative humidity up to 80% at +25 °C.

Safety requirements

It is prohibited to open the housing while the device is powered. Before connecting the device to the mains, make sure that the insulation of the mains cable and housing is intact and that a functional 7.5 A fuse is installed. It is not allowed to change the rating of the installed fuse.

Do not allow chemically active liquids (gasoline, acid, oil, antifreeze, etc.) to come into contact with the charger housing and mains cable. Electrolyte is an aggressive substance. If acid gets on clothing, it must be rinsed with running water. If acid comes into contact with skin or eyes, immediately rinse the affected areas with running water and seek medical attention.

Before charging, remove the battery from the vehicle. Charge storage batteries only in a well-ventilated area. Do not cover the ventilation openings of the device housing. During charging, the temperature of the charger housing may exceed the ambient temperature. Full charging of the battery is possible only if the battery temperature is above +10 °C. In winter, it is recommended to charge the battery indoors.

Operating description

The charger is a high-frequency voltage converter built on a flyback converter circuit. The device includes an electronic protection circuit that provides protection against overload and short circuit. KULON 100 chargers are designed for charging all types of batteries – alkaline, GEL, AGM, WET, GEL, VRLA/SLA with a rated voltage of 12 V.

The car charger has output voltage indication (left green LED) and output current indication (right three-color LED: green indicates a small load current, yellow indicates a medium current of about 2.5 A, red indicates maximum current).

If the storage battery is connected incorrectly (reverse polarity), which must be avoided, the fuse will blow. In this case, both green LEDs will remain on, but no voltage will be present at the output terminals. You should independently purchase a 7.5 A fuse and install it. The charger should continue to operate normally. After replacing the fuse, it is recommended to check the no-load voltage of the charger (voltage at the output terminals without a connected load).

The charger has an operating algorithm that ensures optimal charging speed while preventing dangerous overvoltage for the battery and protecting it from overcharging.

A fully discharged 55 Ah battery is charged in 10–12 hours, after which the charger switches to maintenance charging with a small current. We recommend charging the battery once a year for 18–24 hours for better restoration of electrode plates, while monitoring the electrolyte level and density.

If the AC mains supply is temporarily interrupted, the charging process stops; when the mains voltage is restored, charging continues automatically.

Figure 1 shows graphs of the charging process of a typical fully discharged 55 Ah battery using the Kulon-100 charger.

Fig.1. Charging graph of a typical battery.

Operating procedure

1. Connect the device clamps to the battery terminals, observing polarity. Connect the red wire with the (+) clamp to the (+) terminal of the battery or load. Connect the black wire with the (-) clamp to the (-) terminal of the battery or load. Make sure the wires are securely connected and polarity is observed. If the battery is properly connected and the fuse is intact, the green LED “Power/Battery connected” will light up.

2. Connect the charger to the AC mains – the three-color indicator will light up, indicating that charging or load operation has begun. If the green LED “Power/Battery connected” is off, while the right LED lights up red (and the charger emits a faint sound), this indicates a short circuit that must be eliminated. As the battery charges, the current decreases automatically. At approximately 14.4 V, the right indicator gradually changes from red to yellow. Charging is completed when the indicator turns green (approximately 14.7 V). For cold or faulty batteries, some charging stages may be skipped (fast transition from red to green) or prolonged.

3. Disconnect the charger from the AC mains, then disconnect the battery or load. When connecting an already fully charged battery, the right three-color LED will almost immediately switch from red to green. This may also occur when connecting a completely degraded battery, a battery with an allowable charging current below 2 A, or a cold battery.

4. During normal load operation or battery charging, the left LED always remains lit, and the right LED changes color depending on the output current. If both LEDs are green and the connected device is not functioning, check all connections and fuses in both the charger and the connected device.

5. Simultaneous charging of several batteries is not allowed.

6. It is allowed to connect both a battery and a load simultaneously, as well as parallel operation of several chargers on one load.

Warranty obligations

The manufacturer guarantees compliance of the device with technical requirements and its operability when all instructions in the operating manual are followed.

This warranty card guarantees repair within 7 days. The warranty period of the charger is 12 months from the date of purchase through retail sales. If repair is not possible, the device must be replaced with an equivalent one. Without a warranty card, in case of mechanical damage, or if malfunction is caused by improper use, claims are not accepted, and warranty repair is not performed. The warranty does not cover natural wear. The warranty card must include the store name, stamp, and date of sale.

Warranty service is carried out at: St. Petersburg, Litovskaya St., 10, tel. 295-21-41.

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