OptiMATE TM400A 6V Automatic Charger Instruction Manual

OptiMATE TM400A 6V Automatic Charger

MODEL: TM400a, TM401a (v2), TM407a

AC: 100 – 240VAC 50-60Hz
0.19A @ 100V  / 0.12A @ 240V
DC: 6V / 12V 0.6A

6V / 12V
STD / AGM / GEL 2 – 28Ah

Automatic charger for 6V & 12V lead-acid batteries

LED

For a discharged 12V battery with voltage below 8V 

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS. IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME, BEFORE USING THE BATTERY CHARGER, YOU COMPLETELY FAMILIARIZE YOURSELF WITH THESE SAFETY INSTRUCTIONS.
AUTOMATIC BATTERY CHARGER FOR 6V AND 12V LEAD-ACID BATTERIES.
DO NOT USE FOR NiCd, NiMH, Li-Ion OR NON-RECHARGEABLE BATTERIES.

1. GENERAL BATTERY CHARGER PRECAUTIONS.
   CAUTION : DO NOT CONNECT TO GROUND. Do not expose charger to rain or snow. 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. To reduce risk of damage to electric plug and cord/cable, pull by plug rather than cord/cable when disconnecting charger. Do not operate charger with damaged cord or plug – If the cable is damaged, it is essential to have it replaced without delay by the manufacturer, an authorised service agent or a qualified workshop, to avoid danger. Do not operate charger if it has received a sharp blow, been dropped, or has been otherwise damaged in any way; take it to a qualified Service Technician. 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. Before attempting any maintenance or cleaning, to reduce risk of electric shock, unplug the charger from the AC outlet and the battery. Clean only with slightly moist, not wet, cloth. Do not use solvents.

2. AC EXTENSION CORDS/CABLES.
   An extension cord/cable 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 plug of extension cord are the same number, size and shape as those of plug on charger,
   b) the extension cord is properly wired and in good electrical condition, and c) the conductor wire size is large enough for the AC ampere rating of the charger as specified in the table below.

3. WARNING – RISK OF EXPLOSIVE GASES.
   a) Working in the vicinity of a battery is dangerous. Lead-acid batteries generate explosive gasses during normal battery operation. For this reason it is of utmost importance that you follow the instructions each time you use the charger.
   b) To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in vicinity of the battery. Review cautionary marking on these products and on engine.

4. PERSONAL PRECAUTIONS:
   a) Someone should be within range of your voice OR close enough to come to your aid when you work near a lead-acid battery.
   b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
   c) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
   d) If battery acid contacts or enters eye, flood eye with cold running water for at least 10 minutes and get medical attention immediately. If battery acid contacts skin or clothing, wash immediately with soap & water.
   e) NEVER smoke or allow a spark or flame in vicinity of battery or engine.
   f) 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 explosion.
   g) Remove personal metal items such as rings, bracelets, necklaces, and watches when working with any battery. A lead-acid or lithium battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
   h) NEVER charge a frozen battery.

5. CHARGER LOCATION: a) Do not operate charger in a closed-in area or restrict ventilation in any way. b) Locate charger as far away from battery as DC cables permit. c) Never place charger directly above battery being charged; gases from battery can corrode and damage the charger. d) Never allow battery acid to drip on charger when reading gravity or filling battery. e) Do not set a battery on top of charger. IMPORTANT : Place charger on a hard flat surface or mount onto a vertical surface. Do not place on plastic, leather or textile surface.

6. DC CONNECTION PRECAUTIONS: a) Connect and disconnect DC output clips only after removing AC cord from electric outlet. Never allow clips to touch each other. b) Attach clips to battery and chassis as indicated in 8(e), 8(f), and 9(a) through 9(d).
   NOTE : This battery charger has an automatic safety feature that will prevent
   it from operating if the battery has been inversely connected. Remove AC cord
   from electrical outlet, disconnect the battery clips, then reconnect correctly according to the instructions below.

7. PREPARING THE BATTERY:
   a) If the battery is new, before connecting the charger read the battery manufacturer’s safety and operational instructions carefully. If applicable, carefully and exactly follow acid filling instructions.
   b) If it is necessary to remove battery from vehicle to charge, make sure all accessories in the vehicle are off, so as not to cause an arc. First remove grounded terminal (normally marked NEGATIVE (NEG, N,–) from battery first, then the terminal marked POSITIVE (POS, P, +).
   c) Place the battery in a well ventilated area.
   d) Visually check the battery for mechanical defects such as a bulging or cracked casing, or signs of electrolyte leakage. If the battery has filler caps and the plates within the cells can be seen from the outside, examine the battery carefully to try to determine if any cells seem different to the others (for example, with white matter between the plates, plates touching).
   If mechanical defects are apparent do not attempt to charge the battery, have the battery professionally assessed.
   e) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
   f) For lead-acid batteries with removable filler caps, add distilled water in each cell until battery acid reaches level specified by battery manufacturer. This helps purge excessive gas from cells. Do not overfill.
   g) For a battery without cell caps, such as valve regulated lead-acid (VRLA), absorbed glass mat (AGM) lead-acid or Lithium (LiFePO4) batteries, carefully follow manufacturer’s recharging instructions.
   h) Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge.
   i) Determine voltage of battery by referring to vehicle or other user’s manual and before making the battery connections, make sure that the voltage of the battery you are going to charge matches the output voltage of the battery charger.

8. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE AND YOU CHOOSE TO USE BATTERY CLIPS TO CHARGE THE BATTERY. A SPARK
   NEAR A BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:
   a) Position AC and DC cords so as to reduce risk of damage by the vehicle itself or moving engine parts. b) Stay clear of fan blades, belts, chains, sprockets, pulleys, and other vehicle parts that can cause injury to persons or damage to the charger and its cords/cables.
   c) Check polarity of battery posts. On automotive batteries POSITIVE (POS, P, +) battery post usually has larger diameter than NEGATIVE (NEG, N,–) post.
   d) Determine which post of battery is grounded (connected) to the chassis.
   If negative post is grounded to chassis (as in most modern vehicles), see (e). If positive post is grounded to the chassis, see (f).
   e) 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 gage metal part of the frame or engine block.
   f) 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 carburettor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block. g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle chassis, and then remove clip from battery terminal. h) See operating instructions for length of charge information.

9.  FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE OF THE VEHICLE OR HAS BEEN REMOVED FROM THE VEHICLE. A SPARK NEAR THE BATTERY
   MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:
   a) Check polarity of battery posts. The POSITIVE (POS, P, + ) and NEGATIVE (NEG,N, – ) battery posts will be clearly marked.
   b) Connect the POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.
   c) Then connect the NEGATIVE (BLACK) charger clip to the NEGATIVE (NEG, N, -) post of the battery. d) When disconnecting charger, always do so in reverse sequence of connecting procedure & break first connection while as far away from battery as practical.

10.  SAFE USE BY MINORS OR PERSONS WITH REDUCED CAPABILITIES:
    a) This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge only if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.
    b) Choking Hazard. Accessories may present a choking hazard to children. Do not leave children unattended with product or any accessory. The product is not a toy.

11. RADIO FREQUENCY INTERFERENCE: The OptiMate DUO complies with Part 15 of the FCC
    Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
    NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated
    in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

12. PROPOSITION 65, STATE OF CALIFORNIA: Battery posts / terminals, and related accessories may contain chemicals, including lead or sulphuric acid. These materials are known to the State of California to cause cancer and birth defects and other reproductive harm.
    AC INPUT RATING IN AMPERES

Equal to or greater than             But less than

| LENGTH OF CORD, FEET (m)| AWG SIZE OF CORD
---|---|---
2A| 3A| 25 (17.6)

50 (15.2)

100 (30.5)

| 18

18

14

OPTIMATE 1 VOLTMATIC: CONNECTION ACCESSORIES

Two interchangeable connection sets are supplied with the battery charger:

1. A battery lead with metal eyelet lugs for permanent fitment to the battery posts, and re-sealable weatherproof cap on the on the connector that connects to the charger output cable. Consult a professional service agent for assistance in attaching the metal eyelets to the battery posts. Secure the connector with weatherproof cap so that it cannot foul any moving part of the vehicle or the cable can be pinched or damaged by sharp edges.
   IMPORTANT: This battery lead is protected by a fuse. If under any circumstance the fuse blows, do not try and replace the fuse without first identifying and correcting the issue that caused the fuse to blow.

2.  A set of battery clips for charging the battery on or off-vehicle. Read IMPORTANT SAFETY INSTRUCTIONS points 8 or 9 before connecting to battery.

USING THE OPTIMATE 1 VOLTAIC: PROCEEDING TO CHARGE

For safety reasons, the OptiMate output will only activate if a battery retaining at least 4V is connected.
Panel LED:

LED #1 (RED) – Confirms AC Power supply to the charger. The voltmatic processor will select 6V or 12V charge mode according to battery voltage.
LED #1 on: Battery voltage higher than 8V; 12V charge mode is selected.
LED #1 blinking: Battery voltage lower than 8V; 6V charge mode is now selected.

NOTE: A very flat neglected 12V battery measuring less than 8V at the battery terminals will be selected as a 6V battery. To save a low voltage 12V battery, 12V charging mode must be pre-selected as follows:

STEP 1: Disconnect OptiMate 1 from AC power supply.

STEP 2: Wait for LED #1 to go out.

STEP 3: Connect battery clips together.

STEP 4: Reconnect OptiMate 1 to AC power supply.

STEP 5: LED #1 flashes for 3 seconds and then turns on, confirming 12V mode is pre-selected.

STEP 6: Disconnect clips from each other.

STEP 7: Connect OptiMate 1 to the 12V battery. Charging will proceed in 12V mode. NOTE: Once the 12V battery is disconnected after charging OptiMate 1 will return to  voltmatic mode.

LED #2 (YELLOW): Low Volt Save, Charge and Charge verification
Low Volt Save (battery voltage < 12.4V / 6.2V): Current is delivered in pulses and slowly increased to prepare the battery to accept full charge.
Charge (battery voltage ≥ 12.4V / 6.2V): Current of 0.6A is delivered into the battery to increase the voltage up to 14.2 -14.4V for a 12V battery and 7.1 – 7.2V for a 6V battery.
Verification (pulsed absorption, cell equalization): Variable current pulses are delivered to bring all cells to equal and full charge, within the voltage limit of 13.6V for a 12V battery, and 6.8V for a 6V battery.

NOTE: For safety reasons there is an overall charge time limit of 48 hours, after which the program automatically advances to LED #3. See expected charging time below.

VERY FLAT NEGLECTED BATTERIES

Pay particularly close attention to the following which is especially important for relatively small batteries such as those used on motorcycles, lawn tractors, jet-ski’s, snowmobiles and similar: A battery left deep- discharged for an extended period may develop permanent damage in one or more cells. Such batteries may heat up excessively during charging. Monitor the battery temperature during the first hour, then hourly there-after. Check for unusual signs, such as bubbling or leaking electrolyte, heightened activity in one cell compared to others, or hissing sounds. If at any time the battery is uncomfortably hot to touch or you notice any unusual signs, DISCONNECT THE CHARGER IMMEDIATELY.

LED# 3 (GREEN) – 24-7

BATTERY MAINTENANCE

The maintenance charge cycle consists of 30 minute float charge periods alternating with a 30 minute ‘rest’ periods. During the 30 minute charge period current is offered to the battery within a safe voltage limit (“float charge” of 6.8V for a 6V battery and 13.6V for a 12V battery), allowing it to draw what-ever small current is necessary to maintain it at full charge and compensate for any small electrical loads imposed by vehicle accessories or on-board computer, or the natural gradual self-discharge of the battery itself. During “float charge” a continuous LOW CURRENT PULSE IS DELIVERED TO PREVENT SULPHATION, further extending battery power and life.

During the 30 minute ‘rest’ cycle the charger automatically disconnects from the battery and no charge is delivered. The 30 minute charge, 30 minute rest “50% duty cycle” prevents loss of electrolyte in sealed batteries and minimizes gradual loss of water from the electrolyte in batteries with filler caps, and thereby contributes significantly to optimizing the service life of irregularly or seasonally used batteries.

If the OptiMate senses the battery has suddenly lost charge the program will revert back to charge mode (LED #2).
Maintaining a battery for extended periods: The OptiMate will maintain a battery whose basic condition is good, for months at a time. At least once every two weeks, check that the connections between the charger and battery are secure, and, in the case of lead-acid batteries with filler caps on each cell, disconnect the battery from the charger, check the level of the electrolyte and if necessary, top up the cells (with distilled water, NOT acid), then reconnect. When handling batteries or in their vicinity, always take care to observe the SAFETY

WARNINGS described under the section

IMPORTANT SAFETY INSTUCTIONS.

harging time: The time required for the OptiMate 1 VoltMatic to complete a charge on a flat but otherwise undamaged battery is roughly equal to 2x the battery’s Ah rating, so a 12Ah battery should take no more than about 24 hours to progress to LED #3. Deep-discharged batteries may take significantly longer.

ECO POWER SAVING MODE WHEN THE CHARGER IS CONNECTED TO AC SUPPLY: The power converter switches to ECO mode when the charger is not connected to a battery resulting in a very low power draw of less than 0.5W, equivalent to power consumption of 0.012 kWh per day. When a battery is connected to the charger power consumption depends on the current demand of the battery and its connected vehicle / electronic circuitry. After the battery has been charged and the charger is in long term maintenance charge mode (to keep the battery at 100% charge) the total power consumption is estimated to be 0.060 kWh or less per day.

LIMITED WARRANTY

TecMate (International) SA, B-3300 Tienen, Belgium, makes this limited warranty to the original purchaser at retail of this product. This limited warranty is not transferable. TecMate (International) warrants this battery charger for three years from date of purchase at retail against defective material or workmanship. If such should occur the unit will be repaired or replaced at the option of the manufacturer. It is the obligation of the purchaser to forward the unit together with proof of purchase (see NOTE), transportation or mailing costs prepaid, to the manufacturer or its authorized representative.

This limited warranty is void if the product is misused, subjected to careless handling, or repaired by anyone other than the factory or its authorized representative. The manufacturer makes no warranty other than this limited warranty and expressly excludes any implied warranty including any warranty for consequential damages.

THIS IS THE ONLY EXPRESS LIMITED WARRANTY AND THE MANUFACTURER NEITHER ASSUMES NOR AUTHORIZES ANYONE TO ASSUME OR MAKE ANY OTHER OBLIGATION TOWARDS THE PRODUCT OTHER THAN THIS EXPRESS LIMITED WARRANTY. YOUR STATUTORY RIGHTS ARE NOT AFFECTED.
Details at www.tecmate.com/warranty. More information on TecMate products can be found at www.tecmate.com

References

• Home - OptiMate
• TecMate – High Performance Battery Chargers, Tools & Accessories
• TecMate – High Performance Battery Chargers, Tools & Accessories
• Service and Warranty – TecMate

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