Duralast Battery Charger DL-200D Owners Manual

Duralast Battery Charger DL-200D Owners Manual

PLEASE SAVE THIS OWNERS MANUAL AND READ BEFORE EACH USE. This manual will explain how to use the battery charger safely and effectively. Please read and follow these instructions and precautions carefully.

IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS –
   This manual contains important safety and operating instructions.

2. This charger is not intended for use by children.

3. Do not expose the charger to rain or snow.

4. 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.

5. To reduce the risk of damage to electric plug and cord, pull by the plug rather than the cord when disconnecting charger.

6. 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 an extension cord must be used, make sure:

7. The pins on plug of extension cord are the same number, size and shape as those of plug on charger.

8. The extension cord is properly wired and in good electrical condition

9. The wire size is large enough for AC ampere rating of charger as specified in section 8.

10. Do not operate charger with damaged cord or plug – replace the cord or plug immediately.

11. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman.

12. Do not disassemble charger; take it to a qualified serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

13. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

14. WARNING:
    RISK OF EXPLOSIVE GASES.

15. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER.

16. To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of battery. Review cautionary markings on these products and on engine.

PERSONAL SAFETY PRECAUTIONS

1. Consider having someone close enough by to come to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
4. If battery acid contacts skin or clothing,wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately.
5. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
6. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion.
7. Remove personal 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 weld a ring or the like to metal, causing a severe burn.
8. Use charger for charging only 12V LEAD-ACID (STD, AGM or GEL) rechargeable batteries. It is not intended to supply power to a low voltage electrical system other than in a starter-motor application. Do not use battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property.
9. NEVER charge a frozen battery.

PREPARING TO CHARGE

1. 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.
2. Be sure area around battery is well ventilated while battery is being charged.
3. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
4. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve regulated lead acid batteries, carefully follow manufacturer’s recharging instructions.
5. Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.
6. Determine voltage of battery by referring to car owner’s manual and make sure that output voltage selector switch is set at correct voltage. If charger has adjustable charge rate, charge battery initially at lowest rate.

CHARGER LOCATION

1. Locate charger as far away from battery as DC cables permit.
2. Never place charger directly above battery being charged; gases from battery will corrode and damage charger.
3. Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling battery.
4. Do not operate charger in a closed-in area or restrict ventilation in any way.
5. Do not set a battery on top of charger.

DC CONNECTION PRECAUTIONS

1. Connect and disconnect DC output clips only after setting any charger switches to “off” position and removing AC cord from electric outlet. Never allow the clips of charger to touch each other. Clips may be energized and they may spark.
2. Attach clips to battery and chassis, as indicated in sections 6 and 7.

FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

1. Position AC and DC cords to reduce risk of damage by hood, door, or moving engine part.
2. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
3. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger diameter than NEGATIVE (NEG, N,–) post.
4. Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to chassis (as in most vehicles), see (6.5). If positive post is grounded to the chassis, see (6.6).
5. For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.
6. For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.
7. When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle chassis, and then remove clip from battery terminal.
8. See Operating Instructions for length of charge information.

FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

1. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post.
2. Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, –) battery post.
3. Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.
4. Position yourself and free end of cable as far away from battery as possible – then connect NEGATIVE (BLACK) charger clip to free end of cable.
5. Do not face battery when making final connection.
6. When disconnecting charger, always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical.
7. A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

GROUNDING AND AC POWER CORD CONNECTIONS

1. This battery charger is for use on a nominal 120 volt circuit and has a grounded plug. The charger must be grounded, to reduce the risk of electric shock. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. The plug pins must fit the receptacle (outlet). Do not use with an ungrounded system.

2. DANGER: Never alter the AC cord or plug provided – if it does not fit the outlet, have a proper grounded outlet installed by a qualified electrician. An improper connection can result in a risk of an electric shock or electrocution.
   NOTE: Pursuant to Canadian Regulations, use of an adapter plug is not allowed in Canada. Use of an adapter plug in the United States is not recommended and should not be used.

3. USING AN EXTENSION CORD
   The use of an extension cord is not recommended. If you must use an extension cord, follow these guidelines:

   • Pins on plug of extension cord must be the same number, size, and shape as those of plug on charger.
   • Ensure that the extension cord is properly wired and in good electrical condition.
   • Wire size must be large enough for the AC ampere rating of charger, as specified:

AWG-American Wire Gauge

ASSEMBLY INSTRUCTIONS

1. Remove all cord wraps and uncoil the cables prior to using the battery charger.
2. Extend the handle from the retracted position by pulling it upward until it locks into place. (Press the small silver buttons inward, if necessary.)

CONTROL PANEL

RATE SELECTION BUTTON
Use this button to select one of the following:

• 6A<>2A CHARGE/MAINTAIN –

For charging small and large batteries. Not recommended for industrial applications.

• 40A BOOST – For quickly adding energy to a severely discharged or large capacity battery prior to Engine Start.
• 200A ENGINE START – Provides 200 amps for cranking an engine with a weak or run-down battery. Always use in combination with a battery.

START/STOP BUTTON
Press to immediately begin charging your properly connected battery. If the button is not pressed, charging should begin automatically in 30 seconds.

LED INDICATORS
ON (yellow/orange) LED lit:
The charger is charging the battery.
CHARGED/MAINTAINING (green) LED lit: The battery is fully charged and the charger is in maintain mode.
CLAMPS REVERSED/BAD BATTERY (red) LED flashing: The connections are reversed.

CLAMPS REVERSED/BAD BATTERY (red) LED lit: The charger has detected a problem with the battery.
See Troubleshooting for more information.
NOTE: See Operating Instructions for a complete description of the charger modes.

OPERATING INSTRUCTIONS

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE AN EXPLOSION. CHARGING A BATTERY IN THE VEHICLE

1. Turn off all the vehicle’s accessories.
2. Keep the hood open.
3. Clean the battery terminals.
4. Place the charger on a dry, non-flammable surface.
5. Lay the AC/DC cables away from any fan blades, belts, pulleys and other moving parts.
6. Connect the battery, following the precautions listed in sections 6 and 7.
7. Connect the charger to a live, grounded 120V AC outlet.
8. Select the charge rate.
9. Press the START button to begin charging immediately. If START button is not pressed within thirty seconds after unit was first powered up, and the charger detects a battery that is properly connected, the charging process will automatically begin and finish. Unit will automatically use the Boost rate for the first 10 minutes and then change to the Charge rate, if selected.
10. When charging is complete, indicated by Charged/Maintaining LED lit, or if you are done, press STOP button, disconnect the charger from the AC power, disconnect the clamp attached to vehicle’s chassis, and finally remove the clamp from battery terminal.

CHARGING A BATTERY OUTSIDE OF THE VEHICLE

1. Place battery in a well-ventilated area.
2. Clean the battery terminals.
3. Connect the battery, following the precautions listed in sections 6 and 7.
4. Connect the charger to a live grounded 120V AC outlet.
5. Select the charge rate.
6. Press the START button to begin charging immediately. If START button is not pressed within thirty seconds after unit was first powered up, and the charger detects a battery that is properly connected, the charging process will automatically begin and finish. Unit will automatically use the Boost rate for the first 10 minutes and then change to the Charge rate, if selected.
7. When charging is complete, indicated by Charged/Maintaining LED lit, or if you are done, press STOP button, disconnect the charger from the AC power, disconnect the negative clamp, and finally the positive clamp.
8. A marine (boat) battery must be removed and charged on shore.

BATTERY CHARGING TIMES
Charge time will depend on battery size, as depicted in the chart below.

Times are based on a 50% discharged battery and may change, depending on age and condition of battery.

AUTOMATIC CHARGING MODE
When the 6<>2A Charge or Boost rate is selected, the charger switches to the maintain mode automatically after the battery is charged.

ABORTED CHARGE
If charging cannot be completed normally, charging will abort. When charging aborts, the charger’s output is shut off and the Bad Battery (red) LED will light. Do not continue attempting to charge this battery. Have it checked or replaced.

DESULFATION MODE
Desulfation could take 8 to 10 hours. If desulfation fails, charging will abort and the Bad Battery (red) LED will light.

COMPLETION OF CHARGE
Charge completion is indicated by the Charged/Maintaining (green) LED. When lit, the charger has switched to the maintain mode of operation.

MAINTAIN MODE
(FLOAT MODE MONITORING)
When the Charged/Maintaining (green) LED is lit, the charger has started maintain mode. In this mode, the charger keeps the battery fully charged by delivering a small current when necessary. If the charger has to provide an excessive maintain current for a continuous 12 hour period, it will
go into abort mode (see Aborted Charge section). This is usually caused by a drain on the battery or the battery could be bad.

MAINTAINING A BATTERY
This unit charges and maintains 12V batteries, keeping them at full charge. NOTE: The maintain mode technology allows you to safely charge and maintain a healthy battery for extended periods of time. However, problems with the battery, electrical problems in the vehicle, improper connections or other unanticipated conditions could cause excessive current draws. As such, occasionally monitoring your battery and the charging process is required.

USING THE ENGINE START FEATURE Your battery charger can be used to jump start your car if the battery is low. Follow all safety instructions and precautions for charging your battery. Wear complete eye protection and protective clothing.

WARNING: Using the Engine Start feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle’s electrical system.

NOTE: If you have charged the battery and it still will not start your car, do not use the Engine Start feature, or it could damage the vehicle’s electrical system. Have the battery checked.

1. With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in Follow These Steps When Battery is Installed in Vehicle.
2. Connect the charger to a live grounded 120V AC outlet.
3. With the charger plugged in and connected to the battery and chassis, press the Rate Selection button until the Engine Start LED is lit, and then press the START button.
4. Crank the engine until it starts or 7 seconds pass. If the engine does not start, repeat. Do not crank during the cool down period (see below). This allows the charger and battery to cool down. NOTE: During extremely cold weather, or if the battery is under 2 volts, charge the battery for 5 minutes before cranking the engine.
5. If the engine fails to start, charge the battery for 5 more minutes before attempting to crank the engine again.
6. After the engine starts, unplug the AC power cord before disconnecting the battery clamps from the vehicle.
7. Clean and store the charger in a dry location.

NOTE: If the engine does turn over but never starts, there is not a problem with the starting system; there is a problem somewhere else with the vehicle. STOP cranking the engine until the other problem has been diagnosed and corrected.

ENGINE STARTING NOTES
During the starting sequence listed above, the charger is set to one of four states:

• Wait for ready – The charger charges the battery for 2 minutes before the Wait for Cranking state. While waiting for ready, the engine can be cranked. For severely discharged batteries, it is not recommended to crank during this time.
• Wait for cranking – The charger waits until the engine is actually being cranked before delivering the amps for engine start.
• Cranking – When cranking is detected, the charger will automatically deliver up to its maximum output as required by the starting system for up to 7 seconds.
• Cool Down – After repeated cranking during a 3-minute ready period, the charger enters a mandatory 3 minute (180 second) cool down state. After 2 hours of Engine Starting, the unit will automatically exit from the charging mode, just as if the STOP button had been pressed; the ON LED will not be lit.

POWER-UP AUTO-START
This charger is equipped with an auto-start feature, which is triggered only when the charger is first powered up. If the START button is not pressed within 30 seconds, the unit will search for a battery. If the unit detects a battery that is properly connected,the unit will set the rate to Boost, and it will automatically start the charge process. The On (yellow/orange) LED will light.

FAN OPERATION
The fan will operate as needed and it is normal for the fan to sometimes operate continuously. Keep the area near the charger clear of obstructions to allow the fan to operate efficiently.

MAINTENANCE AND CARE

A minimal amount of care can keep your battery charger working properly for years.

• Clean the clamps each time you are finished charging. Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion.
• Occasionally cleaning the case of the charger with a soft cloth will keep the finish shiny and help prevent corrosion.
• Coil the input and output cords neatly when storing the charger. This will help prevent accidental damage to the cords and charger.
• Store the charger unplugged from the AC power outlet in an upright position.
• Store inside, in a cool, dry place. Do not store the clamps on the handle, clipped together, on or around metal, or clipped to the cables.

TROUBLESHOOTING

AC outlet.

Check power cord and extension cord for loose fitting plug.

Engine start does not work.| Drawing more than the Engine Start rate.

Failure to wait 3 minutes (180 seconds) between cranks.
The charger may be overheated.

Battery may be severely discharged.

| Crank time varies with the amount of current drawn. If cranking draws more than the Engine Start rate, crank time may be less than 5 seconds.

When the Engine Start LED blinks, wait 3 minutes of rest time before the next crank.

The thermal protector may have tripped and needs a little longer to reset. Make sure the charger vents are not blocked. Wait and try again.

On a severely discharged battery, use the Boost rate for 10 to 15 minutes, to help assist in cranking.

The red Clamps Reversed/ Bad Battery LED is lit.| The battery voltage is still under 10V (for a 12V battery) or 5V (for a 6V battery) after 2 hours of charging.

The charger cannot desulfate the battery.

The battery was unable to reach the “full charge” voltage.

The charger was unable to keep the battery fully charged in maintain mode.

The charger detected that the battery may be getting too hot (thermal runaway).

The battery voltage dropped too low during the maintain mode.

| The battery could be bad. Have it checked or replaced.

The battery could not be desulfated; have it checked or replaced.

May be caused by trying to charge a large battery or bank of batteries on too low of a current setting. Try again with a higher current setting or have the battery checked or replaced.

The battery won’t hold a charge. May be caused by a drain on the battery or the battery could be bad. Make

sure there are no loads on the battery. If there are remove them. If there are none,

have the battery checked or replaced.

The charger automatically shuts the current off if it detects the battery may be getting too hot. Have the battery checked or replaced.

May be caused by a drain on the battery or the battery

could be bad. Make sure there are no loads on the battery.

If there are remove them.

If there are none, have the battery checked or replaced.

---|---|---

BEFORE RETURNING FOR REPAIRS

If these solutions do not eliminate the problem,or for more information about troubleshooting, call:
Schumacher Electric Corporation Customer Service
1-800-621-5485
Return products under warranty to your local AutoZone store.

SPECIFICATIONS

Input ……………………………120V AC @ 60Hz, 10A max. continuous, 48A max. intermittent
Output …………………………..12V@ 2A/40A cont., 6A int.; 60 sec. max on, 120 sec. min off 200A int.; 5 sec. max. on, 180 sec. min. off

LIMITED WARRANTY

WARRANTY NOT VALID IN MEXICO.
SCHUMACHER ELECTRIC CORPORATION, 801 BUSINESS CENTER DRIVE, MOUNT PROSPECT, IL 60056-2179, MAKES THIS LIMITED WARRANTY TO THE ORIGINAL RETAIL PURCHASER OF THIS PRODUCT. THIS LIMITED WARRANTY IS NOT TRANSFERABLE OR ASSIGNABLE.
Schumacher Electric Corporation (the “Manufacturer”) warrants this battery charger for two (2) years from the date of purchase at retail against defective material or workmanship that may occur under normal use and care. If your unit is not free from defective material or workmanship, Manufacturer’s obligation under this warranty is solely to repair or replace your product with a new or reconditioned unit at the option of the Manufacturer. It is the obligation of the purchaser to forward the unit, along with proof of purchase and mailing charges prepaid to the Manufacturer or its authorized representatives in order for repair or replacement to occur.
Manufacturer does not provide any warranty for any accessories used with this product that are not manufactured by Schumacher Electric Corporation and approved for use with this product. This Limited Warranty is void if the product is misused, subjected to careless handling, repaired, or modified by anyone other than Manufacturer or if this unit is resold through an unauthorized retailer.
Manufacturer makes no other warranties, including, but not limited to, express, implied or statutory warranties, including without limitation, any implied warranty of merchantability or implied warranty of fitness for a particular purpose. Further, Manufacturer shall not be liable for any incidental, special or consequential damage claims incurred by purchasers, users or others associated with this product, including, but not limited to, lost profits, revenues, anticipated sales, business opportunities, goodwill, business interruption and any other injury or damage. Any and all such warranties, other than the limited warranty included herein, are hereby expressly disclaimed and excluded. Some states do not allow the exclusion or limitation of incidental or consequential damages or length of implied warranty, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and it is possible you may have other rights which vary from this warranty.

THIS LIMITED WARRANTY IS THE ONLY EXPRESS LIMITED WARRANTY AND THE MANUFACTURER NEITHER ASSUMES OR AUTHORIZES ANYONE TO ASSUME OR MAKE ANY OTHER OBLIGATION TOWARDS THE PRODUCT OTHER THAN THIS WARRANTY.
Distributed by:
Best Parts, Inc., Memphis, TN 38103

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