Battery Chargers 97-1 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 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 service person.
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.
a. 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.
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 the 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 the charger for charging only 6V and 12V LEAD-ACID (Standard, AGM, or deep-cycle) or 12V lithium-ion (LiFePO4) 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 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.
3.2 Be sure the area around battery is well ventilated while battery is being charged.
3.3 Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
3.4 If applicable, 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 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 the electric outlet. Never allow clips to touch each other.
5.2 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:
6.1 Position AC and DC cords to reduce the risk of damage by the 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 battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from the 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.
6.6 For a positive-grounded vehicle, connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from the 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 charger, turn switches to off, disconnect AC cord, remove the clip from vehicle chassis, and then remove the clip from the battery terminal.
6.8 See Operating Instructions for the 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:
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 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. 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.
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 thirty seconds.
CHARGING STATUS LED INDICATORS
CHARGING (yellow/orange) LED-lit: The charger is charging the battery.
CHARGED (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.
DIGITAL DISPLAY
The display will show the battery voltage when the charger is not charging a battery. When it goes into charging mode, the display will automatically change to ON (to show
charging has started) and then show the percent-of-charge of the battery being charged and either 6 or 12 (the voltage of the battery, determined by the charger). If you
manually stop the charging process (by pressing the START/STOP button) before the battery is fully charged, the display will show OFF.
NOTE: During charging, the display will go into sleep mode and will not show the percentage of charge or voltage of the battery. To turn the display back on, press any button.
Voltage – The Digital Display shows the voltage at the charger battery clamps in DC volts, or the voltage of the battery, depending on what mode the charger is in.
% – The Digital Display shows an estimated charge percent of the battery connected to the charger battery clamps.
CHARGE RATE
The charger will automatically adjust the charging current, based on battery size, in order to charge the battery completely, efficiently, and safely.
RATE SELECTION BUTTON
Use this button to set the maximum charge rate. Press the button until the desired charge rate is selected.
3A – For charging small batteries, such as those commonly used in garden tractors, snowmobiles, and motorcycles. Also used to maintain fully charged large batteries.
12A – For charging automotive, marine, and light truck batteries. Not intended for industrial applications.

BATTERY TYPE BUTTON
Use this button to select the battery type.
NOTE: Each of the three settings applies to regular and deep-cycle batteries.
Standard – Used in cars, trucks, and motorcycles, these batteries have vent caps and are often marked “low maintenance” or “maintenance-free”. This type of battery is
designed to deliver quick bursts of energy (such as starting engines) and has a greater plate count. The plates are thinner and have somewhat different material compositions.
AGM – The Absorbed Glass Mat construction allows the electrolyte to be suspended in close proximity with the plate’s active material. In theory, this enhances both the discharge and recharge efficiency. The AGM batteries are a variant of Sealed VRLA (valve-regulated lead-acid) batteries. Popular uses include high-performance engine
starting, power sports, deep-cycle, solar, and storage batteries.
LITH (Lithium-Ion, LiFePO4 only) – The LiFePO4 (Lithium Iron Phosphate) battery is lithium-ion based and offers good safety characteristics. The LiFePO4 cell has a very constant discharge voltage. This allows the cell to deliver virtually full power until it is discharged. Because of the nominal 3.2 VDC output, four cells can be placed in series for a nominal voltage of 12.8 V. This comes close to the nominal voltage of six-cell lead-acid batteries. This makes the LiFePO4 a good replacement for lead-acid batteries in applications such as automotive and solar. Like a gel cell, the LiFePO4 cell is sensitive to overcharging. Its cells are balanced before they are assembled, and an internal protection system is implemented, preventing too deep a discharge.

OPERATING INSTRUCTIONS

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE AN EXPLOSION.
IMPORTANT: Do not start the vehicle with the charger connected to the AC outlet, or it could result in damage to the charger and your vehicle.
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. Access the battery; keep the area 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 AC outlet.
8. Select the battery type and charge rate.
9. Charging will begin within thirty seconds and finish automatically. (Press the START/STOP button to begin charging immediately.)
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 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 AC outlet.
5. Select the battery type and charge rate.
6. Charging will begin within thirty seconds and finish automatically. (Press the START/STOP button to begin charging immediately.)
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 onshore.

AUTOMATIC CHARGING MODE
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. The digital display will show an error code (see the Troubleshooting section for a description of the error codes). Do not continue attempting to charge this battery. Check the battery and replace, if necessary.
DESULFATION MODE
Desulfation could take 8 to 10 hours. If desulfation fails, charging will abort, the display will show “F02” and the Bad Battery (red) LED will stay on.
COMPLETION OF CHARGE
Charge completion is indicated by the Charged (green) LED. When lit, the charger has switched to the maintenance mode of operation.
MAINTAIN MODE (FLOAT-MODE MONITORING)
When the Charged (green) LED is lit, the charger has started to 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 its 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. Make sure there are no loads on the battery. If there are, remove them. If there are none, have the battery checked or replaced.

MAINTAINING A BATTERY
This unit charges and maintains 6-volt and 12-volt batteries. 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 BATTERY VOLTAGE TESTER

1. With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in previous sections.
2. Plug the charger AC power cord into the AC outlet.
3. If necessary, press the Battery Type button until the correct type is indicated.
4. Read the voltage on the digital display. Keep in mind that this reading is only a battery voltage reading; a false surface charge may mislead you. Compare the reading to the chart below.

6V Battery Voltage Reading| 12V Battery Voltage Reading| Battery Condition
---|---|---
6.4 or more| 12.8 or more| Charged
6.1 to 6.3| 12.2 to 12.7| Needs charging
Less than 6.1| Less than 12.2| Discharged

POWER-UP IDLE TIME LIMIT
If no button is pressed within 30 seconds after the battery charger is first powered up, the charger will automatically switch from tester to charger if a battery is connected.
In that case, the charger will be set to charge at the 12A rate and lithium battery type.

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

TROUBLESHOOTING/ERROR CODES

Error Codes

CODE| DESCRIPTION|

REASONISOLUTION

---|---|---
| The battery voltage is still under 10V (for a 12V battery) or 5V (for a 6V battery) after 2 hours of charging.|

The battery could be bad. Has it been checked or replaced?

| The charger cannot desulfate the battery.| The battery could not be desulfated; have it checked or replaced.
| The battery was unable to reach the “full charge” voltage.| 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 connections to the battery are reversed.| The battery is connected backward. Unplug the charger and reverse the connections to the battery.
| The charger was unable to keep the battery fully charged in maintain mode.|

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.

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

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

If you get an error code, check the connections and settings and/or replace the battery.
Troubleshooting

PROBLEM

| POSSIBLE CAUSE|

SOLUTION

---|---|---
Battery clamps do not spark when touched together.|

The charger is equipped with an auto-start feature. It will not supply current to the battery clamps until a battery is properly connected. The clamps will not spark if touched together.

| No problem; this is a normal condition.
The charger will not turn on when properly connected.| AC outlet is dead.
Poor electrical connection.
Battery is defective.| Check for an open fuse or circuit breaker supplying an AC outlet.
Check power cord and extension cord for the loose-fitting plug.
Has the battery been checked?
I cannot select a 6V or 12V setting.| The charger is equipped with Auto Voltage Detection, which automatically detects the voltage and charges the battery.| No problem; this is normal.
The battery is correctly connected, but the
Charging LED did not light immediately.| If the START/STOP button is not pressed, charging
should begin in thirty seconds.| No problem; this is normal.
The battery is properly connected, but the Charging LED never lit.| The battery voltage is low.| Press the START/STOP button to start charging.
The Bad Battery LED is lit.|

The battery voltage is still below 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.
Lack of progress is detected and battery voltage is below 14.2V (for a 12V battery) or 7.1V (for a 6V battery).
The battery’s initial voltage is below 12.2V (for a 12V
battery) or 6.1V (for a 6V battery) and the total input is less than 1.5 Ah.
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.
The battery may be defective. Has the battery been checked or replaced?
The battery may be overheated. If so, allow the battery to
cool. The battery may be too large or have a short circuit.
Has the battery been checked or replaced?
The battery capacity is too low, or the battery is too old.
Has it been 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.

 BEFORE RETURNING FOR REPAIRS

For REPAIRS OR RETURNS, visit 365rma.com
Visit batterychargers.com for Replacement Parts.

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.

References

• 365RMA.COM
• Home Page - Schumacher Electric

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