Chargers Automatic Battery Charger Owner’s Manual

Automatic Battery Charger
OWNERS MANUAL

PLEASE SAVE THIS OWNERS MANUAL AND READ IT 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 – SAVE THESE INSTRUCTIONS

1.1 SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions.
1.2 Keep out of reach of children.
1.3 Do not expose the charger to rain or snow.
1.4 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.
1.5 To reduce the risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger.
1.6 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:
• The pins on the plug of the extension cord are the same number, size, and shape as those of the plug-on charger.
• The extension cord is properly wired and in good electrical condition.
• The wire size is large enough for the AC ampere rating of charger as specified in section 8.
1.7 Do not operate charger with a damaged cord or plug – replace the cord or plug immediately.
1.8 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.
1.9 Do not disassemble the 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.
1.10 To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
1.11 WARNING: RISK OF EXPLOSIVE GASES.
WORKING IN THE 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.
b. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on these products and on the engine.

 PERSONAL SAFETY PRECAUTIONS

2.1 Consider having someone close enough by to come to your aid when you work near a lead-acid battery.
2.2 Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
2.3 Wear complete eye protection and clothing protection. Avoid touching eyes while working near the battery.
2.4 If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately.
2.5 NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.
2.6 Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit a battery or another electrical part that may cause an explosion.
2.7 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.
2.8 Use charger for charging 6V and 12V LEAD-ACID (STD, AGM, GEL, or deep- cycle) 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 a 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.
2.9 NEVER charge a frozen battery.

PREPARING TO CHARGE

3.1 If necessary to remove the battery from the vehicle to charge, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.
3.2 Be sure the area around the battery is well ventilated while the battery is being charged.
3.3 Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
3.4 Add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve-regulated lead-acid batteries, carefully follow the manufacturer’s recharging instructions.
3.5 Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.
3.6 Determine voltage of battery by referring to car owner’s manual and make sure that output voltage selector
switch is set at the correct voltage. If the charger has an adjustable charge rate, charge the battery initially at the lowest rate.

CHARGER LOCATION

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

DC CONNECTION PRECAUTIONS

5.1 Connect and disconnect DC output clips only after setting any charger switches to “off” position and removing AC cord from electric outlet. Never allow clips to touch each other. Clips may be energized and they may spark.
5.2 Attach clips to battery and chassis, as indicated in sections 6 and 7.
6. FOLLOW THESE STEPS WHEN THE 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:
6.1 Position AC and DC cords to reduce the risk of damage by hood, door, or moving engine part.
6.2 Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
6.3 Check the polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post. 6.4 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 a positive post is grounded to the chassis, see (6.6).
6.5 For a negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded post of the battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do not connect the clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge
the metal part of the frame or engine block.
6.6 For a positive-grounded vehicle, connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, –) ungrounded post of the battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Do not connect the clip to carburetor, fuel lines, or sheet- metal body parts. Connect
to a heavy gauge metal part of the frame or engine block.
6.7 When disconnecting the charger, turn the switch off, disconnect the AC cord, remove the clip from the vehicle chassis, and then remove the clip from the battery terminal.
6.8 See Operating Instructions for the length of charge information.
7. FOLLOW THESE STEPS WHEN THE 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:
7.1 Check the polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post.
7.2 Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, –) battery post.
7.3 Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of the battery.
7.4 Position yourself and the free end of the cable as far away from the battery as possible – then connect the NEGATIVE (BLACK) charger clip to the free end of the cable.
7.5 Do not face battery when making the final connection.
7.6 When disconnecting the charger, always do so in the reverse sequence of connecting procedure and break the first connection while as far away from the battery as practical.
7.7 A marine (boat) battery must be removed and charged onshore. To charge it on board requires equipment specially designed for marine use.

 GROUNDING AND AC POWER CORD CONNECTIONS

8.1 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.
8.2 DANGER : Never alter the AC cord or plug provided – if it does not fit the outlet, have a properly 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, the 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.
8.3 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 the plug of the extension cord must be the same number, size, and shape as those of the 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

9.1 Remove all cord wraps and uncoil the cables prior to using the battery charger.

CONTROL PANEL

START/STOP BUTTON
Press to immediately begin charging your properly connected battery. If the button is not pressed, charging should begin in ten minutes.
LED INDICATORS
POWER (green) LED: The charger is connected to an AC outlet.
CHARGE/BOOST/ENGINE START (yellow/orange) LED-lit: The charger is charging or boosting the battery, or the unit is ready for Engine Start.
CHARGED/MAINTAINING (green) LED-lit: The battery is fully charged and the charger is in maintenance mode.
CLAMPS REVERSED (red) LED flashing: The connections are 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.
RATE SELECTION BUTTON
Use this button to select one of the following:
6<>2A CHARGE – For charging small and large batteries. Not recommended for industrial applications.
BOOST – For quickly adding energy to a severely discharged or large capacity battery prior to Engine Start. The unit will automatically switch to 6A<>2A Charge after the Boost operation has been completed.
ENGINE START – Provides additional amps for cranking an engine with a weak or run-down battery.
Always use in combination with a battery.

OPERATING INSTRUCTIONS

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE AN EXPLOSION.
NOTE: This charger is equipped with an auto-start feature. Current will not be supplied to the battery
clamps until a battery is properly connected. The clamps will not spark if touched together.

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 battery type and charge rate.
9.  Press the START/STOP button to begin charging immediately. If the button is not pressed, charging will begin within ten minutes. It will finish automatically.
10.  When charging is complete, disconnect the charger from the AC power, remove the clamp from the vehicle’s chassis, and then remove the clamp from the battery terminal.

CHARGING A BATTERY OUTSIDE OF THE VEHICLE

1. Place the 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 battery type and charge rate.
6. Press the START/STOP button to begin charging immediately. If the button is not pressed, charging will begin within ten minutes. It will finish automatically.
7. When charging is complete, 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.

CHARGE RATE

The charger will automatically adjust the charging current, based on battery size, in order to charge the battery completely, efficiently, and safely.
AUTOMATIC CHARGING
When an Automatic Charge is performed, the charger switches to the maintenance mode automatically after the battery is charged.

BATTERY CHARGING TIMES

Times are based on a 50% discharged battery and may change, depending on the age and condition of the battery.
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. Has it been checked or replaced?
DESULFATION MODE
While desulfation is in progress, the Charge/Boost/Engine Start and Bad Battery LEDs will be lit. Desulfation could take 8 to 10 hours. If desulfation fails, charging will abort and the Bad Battery (red) LED will remain lit.
COMPLETION OF CHARGE
Charge completion is indicated by the Charged/Maintaining (green) LED. When lit, the charger has switched to the maintenance mode of operation.
MAINTAIN MODE (FLOAT MODE MONITORING )
When the Charged/Maintaining 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 ts maximum 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 6V and 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 will damage 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. Has the battery been 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 of the vehicle, set the Rate Selection to the Engine Start position. The Charge/Boost/Engine Start LED will be lit.
4. Press the START/STOP button to begin Engine Start. Engine Start will not begin without pressing the START/STOP button.
5.  Wait 2 minutes before cranking the engine.
6. Crank the engine until it starts or 3 seconds pass. If the engine does not start, wait 3 minutes before cranking again. This allows the charger and battery to cool down. The Engine Start LED will blink during the 3-minute cool-down. NOTE: During extremely cold weather, or if the battery is under 2 volts, use the Boost rate for 5 minutes before cranking the engine.
7. If the engine fails to start, charge the battery for 5 more minutes before attempting to crank the engine again.
8. After the engine starts, unplug the AC power cord before disconnecting the battery clamps from the vehicle.
9.  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.

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 clipped together, clipped to the handle, on or around metal, or clipped to the cables.

TROUBLESHOOTING

PROBLEM

| POSSIBLE CAUSE|

SOLUTION

---|---|---
Battery clamps do not spark when touched together.| The START/STOP button has not been pressed.| Press the START/STOP button.
The Power LED does not light when the charger is properly connected.| AC outlet is dead. Poor electrical connection.| Check for open fuse or circuit breaker supplying AC outlet. Check power cord and extension cord for the loose fitting plug.
Short or no start cycle when cranking engine.| No power at the receptacle.
AC cord and/or extension cord are loose.
The clamps are not making a good connection.
Failure to wait 3 minutes (180 seconds) between cranks. The battery may be severely discharged.
The battery is drawing more than the Engine Start rate. The charger may be overheated.| Check for open fuse or circuit breaker supplying AC outlet. Check power cord and extension cord for the loose fitting plug. Check for poor connection at battery and frame. Wait 3 minutes of rest time before the next crank, to allow the battery and charger to cool down. On a severely discharged battery, use the Boost setting for a few minutes, to help assist in cranking. Crank time varies with the amount of current drawn. If cranking draws more than the Engine Start Rate, crank time may be less than 3 seconds. The thermal protector may have tripped and needed a little longer to close. Make sure the charger vents are not blocked. Wait and try again.

PROBLEM

| POSSIBLE CAUSE|

SOLUTION

---|---|---
The battery is properly connected, but the Charge/ Boost/Engine Start LED is never lit.| The battery voltage is low.| Press the START/STOP button to start charging.
The Charge/Boost/Engine Start and bad Battery LEDs are lit.| The battery is sulfated.| The charger is in desulfation mode. Continue charging for several hours. If not successful, have the battery checked.
The 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. (or) In maintain mode, the output current is more than 1.5A for 12 hours.
Desulfation was unsuccessful The battery voltage drops to below 12.2V (for a 12V battery) or 6.1V (for a 6V battery) in Maintain Mode.| The battery may be defective. Make sure there are no loads on the battery. If there are, remove them. If there are none, have the battery checked or replaced. To reset the charger, unplug from the AC outlet, wait a few moments, and plug it back in. The battery may be defective. Have the battery checked or replaced. The battery won’t hold a charge. It 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.

LIMITED WARRANTY

For information on our one-year limited warranty, please visit batterychargers.com or call 1-800-621-5485 to request a copy.
Go to batterychargers.com to register your product online.

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