OptiMate TM630 4 Quad Premium Program Charger Instruction Manual

OptiMate TM630 4 Quad Premium Program Charger

Specifications

• Model: TM630 / TM631 / TM632 / TM638 TM640 / TM641 / TM642 / TM648
• DC Input: 12V 1.25A
• Battery Types:
  • Pb (Lead-Acid): 1 x 12V STD / AGM-MF / GEL, 4 – 60Ah (max. Ah based on a 48-hour charge)
  • LFP (LiFePO4): 1 x 12.8V LiFePO4, 1.25 – 15Ah (max. Ah based on 12-hour charge)

Product Usage Instructions

Save these instructions. Before using the battery charger, familiarize yourself with the safety instructions.

• AC Input Rating in Amperes:
• Equal to or greater than:
• 2A: But less than 25ft (17.6m) cord length: 18 AWG
• 3A: But less than 50ft (15.2m) cord length: 18 AWG
• 3A: But less than 100ft (30.5m) cord length: 14 AWG
• Working near a battery is dangerous due to explosive gases.
• Follow safety instructions each time.
• To reduce risk, follow instructions from battery and equipment manufacturers.
• Ensure someone is within voice range. DC Connection Precautions
• Connect and disconnect DC output clips after removing the AC cord.
• Never allow clips to touch each other.
• Attach clips as indicated.
• Position cords to avoid damage.
• When disconnecting, turn off switches, disconnect the AC cord, and remove clips from the chassis and battery terminals.
• Refer to operating instructions for charge duration.

FAQ

• Q: Can this charger be used for NiCd or NiMH batteries?
• A: No, this charger is for 12V lead-acid and 12.8V LiFePO4 batteries only. Do not use for NiCd, NiMH, or any other types of Li-Ion or non-rechargeable batteries.

INSTRUCTIONS FOR USE

IMPORTANT: Read completely before charging

• MODEL: TM630 / TM631 / TM632 / TM638 TM640 / TM641 / TM642 / TM648
• AC: 100 – 240V 50-60Hz 0.36A @ 100Vac / 0.19A @ 240Vac
• DC: 12V 1.25A
• 1 x 12V STD / AGM-MF / GEL 4 – 60Ah (max. Ah based on 48-hour charge).
• 1 x 12.8V LiFePO4 1.25 – 15Ah (max. Ah based on 12-hour charge).

Automatic charger for 12V lead-acid & 12.8V LiFePO4 batteries

Automatic charger for 12V lead-acid & 12.8V LiFePO4 batteries

S.O.H. TEST – LFP (LiFePO4) (Program 3 & 4)

• O-1 permanent battery lead – charge battery in the vehicle

• O-04 clips (battery clamps) – charge the battery out of the vehicle

• O-19 adapter with DIN/ISO 4165 plug

O-19 Cable / Adapter

MOUNTING NOTICE

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 12V LEAD-ACID & 12.8V LiFePO4 BATTERIES. DO NOT USE FOR NiCd, NiMH, or any other types of Li-Ion OR NONRECHARGEABLE BATTERIES

GENERAL BATTERY CHARGER PRECAUTIONS

CAUTION: DO NOT CONNECT TO GROUND. Do not expose the 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 the electric plug and cord/cable, pull by the plug rather than the cord/ cable when disconnecting the charger. Do not operate the charger with a damaged cord or plug – If the cable is damaged, it is essential to have it replaced without delay by the manufacturer, an authorized 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 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. Before attempting any maintenance or cleaning, to reduce the risk of electric shock, unplug the charger from the AC outlet and the battery. Clean only with a slightly moist, not wet, cloth.
Do not use solvents.

AC EXTENSION CORDS/CABLES
An extension cord/cable should not be used unless necessary. The use of improper extension cords could result in a risk of fire and electric shock. If an extension cord must be used make sure that: a) the pins on the plug of the extension cord are the same number, size and shape as those of the plug on the 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.

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

WARNING – RISK OF EXPLOSIVE GASES

• 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.
• 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 the vicinity of the battery. Review cautionary markings on these products and on the engine.
• 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 the battery.
• If battery acid contacts or enters the eye, flood the 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.
• NEVER smoke or allow a spark or flame in the vicinity of the battery or engine. f) Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or other electrical part which may cause an 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.
• CHARGER LOCATION: a) Do not operate the charger in a closed-in area or restrict ventilation in any way.
• Locate the charger as far away from the battery as DC cables permit. c) Never place the charger directly above the battery being charged; gases from a battery can corrode and damage the charger. d) Never allow battery acid to drip on the charger when reading gravity or filling the battery.
• Do not set a battery on top of the charger. IMPORTANT :
• Place the charger on a hard flat surface or mount onto a vertical surface. Do not place on plastic, leather or textile surfaces.
• DC CONNECTION PRECAUTIONS: a) Connect and disconnect DC output clips only after removing AC cord from the 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 an electrical outlet, disconnect the battery clips, and then reconnect correctly according to the instructions below.
• 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.
• If it is necessary to remove the battery from the vehicle to charge, make sure all accessories in the vehicle are off, so as not to cause an arc. First remove the grounded terminal (normally marked NEGATIVE (NEG, N,–) from the battery first, then the terminal marked POSITIVE (POS, P, +).

Place the battery in a well-ventilated area

• 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, and plates touching).
• If mechanical defects are apparent do not attempt to charge the battery, have the battery professionally assessed.
• Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
• For lead-acid batteries with removable filler caps, add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer. This helps purge excessive gas from cells. Do not overfill.
• 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.
• Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge.
• Determine the voltage of the battery by referring to a 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.

FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN THE 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:

• Position AC and DC cords to reduce the 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.

• Check the polarity of battery posts. On automotive batteries, the POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N,–) post.

• Determine which post of the battery is grounded (connected) to the chassis.
  If the negative post is grounded to the chassis (as in most modern vehicles), see (e). If the positive post is grounded to the chassis, see (f).

• For a negative-grounded vehicle, connect the POSITIVE (RED) clip from the battery charger to the POSITIVE (POS, P, + ) ungrounded post of the battery. Connect a NEGATIVE (BLACK) clip to the vehicle chassis or engine block away from the battery. Do not connect clip to the carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

• For 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 clip to the carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block. g) When disconnecting the charger, turn the switches to off, disconnect AC cord, remove clip from the vehicle chassis, and then remove a clip from the battery terminal. h) See operating instructions for length of charge information.

FOLLOW THESE STEPS WHEN THE 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

• Check the polarity of battery posts. The POSITIVE (POS, P, + ) and NEGATIVE (NEG,N, – ) battery posts will be marked. b) Connect the POSITIVE (RED) charger clip to the 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 the charger, always do so in the reverse sequence of the connecting procedure & break the first connection while as far away from the battery as practical.
• SAFE USE BY MINORS OR PERSONS WITH REDUCED CAPABILITIES: a) This appliance can be used by children aged 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 done by children without supervision.
• Choking Hazard. Accessories may present a choking hazard to children. Do not leave children unattended with the product or any accessory. The product is not a toy.
• 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, according 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 under the instruction manual, may cause harmful interference to radio communications.
• 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

CONNECTION ACCESSORIES

Three interchangeable connection sets are supplied with the battery charger (illustrations on pages 3 & 4).

1. A battery lead (O-01) with metal eyelet lugs for permanent fitment to the battery posts, with a re-sealable weatherproof cap on the SAE 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 a 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 15A 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. Only replace the fuse with a 15A-rated ATO fuse.

2. A SAE to DIN plug adapter (O-19), to charge through a DIN /ISO 4165 12V power socket:

   • The auxiliary DIN socket on BMW motorcycles (Models: from 2004) can receive charge and maintenance even with the ignition turned off when using a CAN-bus charge mode on the OptiMate4 Quad program.
   • Other vehicles fitted with a DIN socket: if the 12V DIN socket remains continuously powered up after the ignition has been turned off, charge & maintenance can be delivered via the socket.
     Find more DIN/ISO 4165 accessories at www.optimate1.com.

3. A set of battery clips (O-04), is recommended for charging the battery off-vehicle or when the battery needs a recovery charge. Read Section A > IMPORTANT SAFETY INSTRUCTIONS points 8 or 9 before connecting to the battery.

PROCEEDING TO CHARGE

• SELECTING A CHARGE PROGRAM: The OptiMate4 Quad program has four selectable charge programs. A charging program must be selected before making a connection to a battery. Each program has unique charge and test parameters to match the battery’s chemistry and connection method to the battery. The selected program remains in memory after disconnection from the battery, or if AC power is interrupted, or until a new selection is made.

• PROGRAM 1 – Pb (LED #1a): is the direct-to-battery charge program for a lead-acid battery in any condition. All program features are active, including high voltage TURBO and PULSE desulfation mode.

• PROGRAM 2 – Pb (LED #1a) + CAN-bus (LED #2): automatically activates charging for a lead-acid battery through the 12V outlet on vehicles fitted with a CAN-bus controlled 12V outlet, to charge, test and maintain a healthy battery when the vehicle is in storage. All desulfation modes are deactivated. The CAN-BUS (LED #2) blinks until a battery is sensed, and then it turns full on.

• IMPORTANT: FLAT BATTERY (< 5V) – if the vehicle’s lead-acid battery is deep discharged the vehicle’s CAN-bus system will not be able to activate the 12V socket. Remove the battery, inspect it for physical damage or leakage, if deemed acceptable, to recharge select Program 1, and connect the OptiMate4 directly to the battery.

• PROGRAM 3 – LFP (LED #1b): is the direct-to-battery charge program for a LiFePO4 (Lithium Ferrous Phosphate) battery in any condition.

• Use this program to reset a battery fitted with an integrated battery management system (BMS) that protects against deep discharge.

• IMPORTANT! Before proceeding, confirm the battery is connected correctly: Read the section on the previous page: CONNECTING CHARGER TO THE BATTERY.

• Press the push button. After 3 seconds LED #3 lights every second as a special BMS reset pulse is delivered. When the OptiMate 4 senses the battery BMS has reset the reset pulses will automatically discontinue and charging will automatically continue.

• Remove finger from pushbutton.

• BMS not resetting: LED #3 lights briefly and then turns off: A deep discharged battery may not hold sufficient voltage to power its own BMS system. Use the MANUAL RESET: place and hold your finger on the BMS reset button for 10 or more seconds, until the

• the program continues to STEP 4.

• BMS not resetting: LED #8 flashes/blinks.

• The battery is connected in reverse polarity. Correct the connections and try again. 2) The system powered by the battery is preventing the pulse from being delivered. Disconnect or turn off the system and try again. 3) The battery’s BMS or the battery itself may have suffered damage. Have the battery professionally assessed.

• More: 4) An advanced battery management system may include thermal protection that prevents reset if the battery temperature falls outside of the manufacturer-recommended safe operating temperature range. Check the battery manufacturer’s specifications.

• PROGRAM 4 – LFP (LED #1b) + CAN-bus (LED #2): automatically activates charging through the 12V outlet on vehicles fitted with a CAN-bus controlled 12V outlet, to charge, test and maintain a healthy LiFePO4 (Lithium Ferrous Phosphate) battery when the vehicle is in storage. The CAN-BUS (LED #2) blinks until a battery is sensed, and then it turns full on.

• IMPORTANT: FLAT BATTERY (< 9V) – if the vehicle’s LFP/Lithium battery is deep discharged or the battery’s BMS system has turned off power within, the vehicle’s CAN-bus system will not be able to activate the 12V socket. Remove the battery, inspect it for physical damage or leakage, if deemed acceptable, to recharge select Program 3 and connect the OptiMate4 directly to the battery.

• VERY FLAT NEGLECTED BATTERIES: If the battery is deeply discharged (and possibly sulfated), remove it from the vehicle or equipment and inspect the battery before connecting the charger for a recovery attempt. ATTENTION: 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 high-current charging. Monitor the battery temperature during the first hour, then hourly thereafter. Check for unusual signs, such as bubbling or leaking electrolytes, 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.

• CHARGING TIME: Charge time on a flat but otherwise undamaged battery: a 12Ah battery should take no more than about 12 hours to progress to the self-discharge check. Deep-discharged batteries may take significantly longer.

• MAINTAINING A BATTERY FOR EXTENDED PERIODS: OptiMate 4 Quad Program is designed to maintain a battery continuously (24-7); it can be safely left connected to a healthy battery for months at a time.

• RECOMMENDED: At least once every two weeks, check that the connections between the charger and battery are secure. 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 above.

NOTES ON TEST RESULTS: The voltage of a cooled battery is directly proportional to its State Of Charge percentage (SOC%). Immediately following charging a battery may briefly hold a higher voltage, as charging raises the temperature of chemical elements within the battery. A battery recovered from a deep discharged state may need longer to cool and voltage to settle to reflect its true state of charge (SOC%).

TROUBLESHOOTING GUIDE

OPTIMATE 4 WON’T CHARGE| 1)  Battery in the vehicle, CAN-bus program 2 or 4 selected > Battery voltage may be too low to power the vehicle’s CAN-bus system.

a)  Program 2 (Pb): Minimum 5V required. Disconnect the battery from the vehicle, select program 1, and charge directly to the battery.

b)  Program 4 (LFP): Minimum 8.8V min. required. Disconnect the battery from the vehicle, select program 3, and charge directly to the battery.

2)  Poor connection to the 12V outlet – check the connector / try charging directly to the battery.

3)  Outdated CAN-bus programming on the vehicle

– consult with the vehicle manufacturer.

| 4)  Battery in the vehicle, program 1 or 3 selected – Battery voltage is below 0.5V.

a)  Program 1 or 3: Disconnect the battery from the vehicle, wait 5-10 minutes for the battery to recover voltage, and try again.

b)  Program 3 (LFP): Battery with resetable BMS – disconnect the battery from the vehicle and then use the BMS reset procedure.

If OptiMate 4 still does not charge, then have the battery professionally assessed, or replace the battery.

---|---|---
ERROR!

LED 8 flashing/blinking .

| 1) LFP battery in the vehicle, Program 3 or 4: abnormal charging or battery damage has been detected. Disconnect the battery from the vehicle circuity, select program 3, and charge directly to the battery.| 2) Program 3 for Li-Ion / LFP, battery NOT connected to vehicle circuitry. The battery has _permanent damage. Do not charge again.  Replace the battery._
TEST RESULT LED 5 & 6| 1)  Battery in vehicle –

a)  Program 1 & 2 (Pb): STD ‘flooded’ battery: Good > 80%-100%

b)  AGM / LFP battery: 60-80%. Vehicle electronics may be drawing power and discharging the battery. Disconnect from vehicle circuitry and charge again.

| 2)  Battery NOT connected to vehicle circuitry –

a)  Program 1 & 2 (Pb): STD ‘flooded’ battery: State of Health (S.O.H.) is good > 80%-100%.

b)  AGM / LFP battery: 60-80%. The battery has lost power and may need to be replaced soon.

TEST RESULT LED 7, 7 & 8 or 8| 1) Battery in vehicle – Vehicle electronics may be drawing power and discharging the battery. Disconnect from vehicle circuitry and charge again.| 2) Battery NOT connected to vehicle circuitry

– The battery has lost power and should be replaced.

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TEST RESULT

LED 5 – good test result, but the battery is weak.

| 1) Cable connection at battery terminals may be loose. Check all cable connections at the battery and starter solenoid.| 2) A battery wears/loses capacity over time; it may still hold sufficient voltage after charging, but it cannot deliver the cranking amps required to start your vehicle. Have the battery tested / Replace the battery.

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 0.024kWh or less per day.

LIMITED WARRANTY

TecMate (International) SA, B-3300 Tienen, Belgium, offers 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 the 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.
NOTE: Details at www.tecmate.com/warranty.

WARRANTY in Canada, USA, Central America and South America
TecMate North America, Oakville, ON, Canada, as a whole owned subsidiary of TecMate International, assumes the responsibility for product warranty in these regions.
More information on TecMate products can be found at www.tecmate.com.

S.O.H. TEST – Pb (Program 1 & 2)

S.O.H. TEST – LFP (LiFePO4) (Program 3 & 4)

MOUNTING NOTICE

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References

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

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