6007A_Manual_English - Associated Equipment Corp.
Contents
1. TRANSFORMER RECTIFIER WHITE Z m YELLOW z 9 E FAN MOTOR a BLACK 5 7 AMMETER DC CIRCUIT CHARGE 2 x BREAKERS TYPE 1 I NEGATIVE Y POSITIVE 4 SELECTOR s ZK DC CABLE DC CABLE e MODEL 6007A REPAIR PARTS ItemDescription Part No 1 Front E e P E T T 605671 2 Axle WANUR a 610052 3 Wheel w nuts 2 seesseseriessriserrirerrrrrerresernn 611157 4 Rectifier w wiring harness eeen 610985 5 Transformer nianna 611168 6 Fan Blade cccccccccccsssscecccecessssseeseeeeessssseeees 610189 7 Fan Motor w blade cccccccsscscssscecsteeeeeeeeeees 610190 8 DC Circuit Breaker 2 00 eeeeeeeeeeeeeeeteneeee 610987 9 SWITCH S268 ee EB ia E AE EE E 610291 10 Switch ON OFF ON c ccccccccsssssteeeeeeeeeseeees 611167 11 AG COren ineen adre e ei a tyes gas aed 610696 12 DG Cable Satri ierti ae ea E 610820 13 Clamps 1 pair W jAWS s sesseeeeeeeeeeeeeeeeeeeeeeeeee 6199 14 Jaw Kit repairs 1 clamp 610970 15 AO a E E E E E A letabaciai te mies 611155 16 AMMEtET sscan a 610346 17 Back Panel Aone pa iana roia ioiai 610977 18 Right Side Panel ccsssscceseeseeeeseteeeeeseees 611032 19 Front Panel sressnes sman seven 611166 20 Base Panel E E E A AT 610054 Parts Not Shown Left Side Panel ccccccccccccssceeseeeeseeeeseeeeeeeeees 611031 Top Panels oive tenis cee dee ei 611011 Handles naera e e oie tack eee 610753 Clamp Bal ais eho erceaccncuceret dae a Na 610517 MAINTENANCE INSTRUCTI2. If 50 feet 12AWG 100 feet 10AWG 150 feet 8AWG Do not operate the charger with a damaged cord or plug replace them immediately Do not operate the charger if it has received a sharp blow been dropped or otherwise damaged in any way take it to a qualified serviceman Do not disassemble the charger take it to a qualified serviceman when service or repair is required Incorrect reassembly may result in risk of electric shock or fire To reduce the risk of electric shock unplug the charger from the outlet before attempting any maintenance or cleaning Turning off the controls will not reduce this risk 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 EACH TIME BEFORE USING YOUR CHARGER YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY 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 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 clot
3. 1 With AC cord plugged into an outlet the RED light will be on continuously 2 For best results the battery should be fully charged before being used with the Electrical Stability System 3 Set the selector switch to the ESS FLASH setting center 4 Connect the RED clamp to the battery positive connect the black clamp to the grounded frame of the vehicle see Sec 17 on charging batteries installed in a vehicle in the unusual case that the vehicle has a positive ground connect the black clamp to the battery negative post and the red clamp to the chassis 5 When the charger detects the battery voltage is present the GREEN light will light for 4 seconds The YELLOW light will then come on and the unit will start to ramp up the DC current When the charger reaches the safe operating level the YELLOW light will start to blink 6 The unit will not shut off it will maintain the voltage within it s capabilities until the unit is turned off 7 Ifthe voltage should fall below the specified level the YELLOW light will return to continuously on If the unit can not maintain the voltage level for more than 20 seconds then the RED light will start to flash At this point the unit is supplying maximum output and the battery voltage should be monitored to make sure it does not drop below minimum levels required for testing and or programming WIRING DIAGRAM
4. 1 Plug AC cord into outlet Turn POWER switch ON RED light will come on 2 Select mode of operation Flooded or Sealed GEL Most VRLA would be charged with flooded see battery manual for details if in doubt charge with sealed Connect the RED clamp to the positive and the BLACK clamp to the negative The GREEN light will come on for 4 seconds See PREPARING TO CHARGE portion under IMPORTANT SAFETY INSTRUCTIONS of this manual The YELLOW light will come on when the GREEN light goes off and charging will begin If the battery is deeply discharged the YELLOW and GREEN lights will flash on and off for up to 30 minutes Charging will be discontinued if the battery will not accept charge after a reasonable amount of time and the RED light will flash Charging time will depend on the size and state of charge of the battery When charging is complete charger will go into a float mode and the GREEN light will blink ad ONO NOTES ON RECOVERY OF DEEPLY DISCHARGED BATTERIES a Not all deeply discharged batteries can be recovered b Most weak batteries will be detected while charging However some batteries which have been recovered from a deep discharge will maintain an acceptable open circuit voltage but have a reduced capacity under load Always load test or otherwise test a recovered battery to determine if the CCA capacity is within 80 of the rated value 23 OPERATING INSTRUCTIONS ELECTRICAL STABILITY SYSTEM General operation
5. N NOOEY 11 12 13 14 MODEL 6007A 12 VOLT 40 AMP BATTERY CHARGER ANALYZER OPERATOR S MANUAL IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the battery charger you have purchased You may need to refer to these instructions at a later date CAUTION To reduce risk of injury charge only lead acid rechargeable batteries Other types of batteries may burst causing personal injury and property damage Do not expose the charger to rain or snow if specifically warned on the unit not to do so 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 the risk of damage to the electric plug and cord pull by the plug rather than the cord when disconnecting the charger Make sure the cord is located so that it will not be stepped on tripped over or otherwise subjected to damage or stress An extension cord should not be used unless absolutely necessary Use of an improper extension cord could result in a risk of fire and electric shock If an extension cord must be used make sure a That the pins on the plug of extension cord are the same number size and shape as those of the plug on the charger b That the extension cord is properly wired and in good condition and c If the length of the extension cord is less than 25 feet use a 16AWG cord
6. ONS Worn clamps should be replaced Worn parts can lead to poor connections and present a safety hazard See parts list for part number of D C Cord kit Any Maintenance or repair of this unit that involves disassembly of the cabinet should be done only by a qualified serviceman Incorrect reassembly may result in a risk of electric shock when the unit is subsequently used
7. d vehicle connect NEGATIVE BLACK clamp from the battery charger to the NEGATIVE NEG N ungrounded post of the battery Connect POSITIVE RED clamp to the vehicle chassis or engine block away from the battery Do not connect the clamp 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 the AC cord remove the clamp from the vehicle chassis and then remove the clamp from the battery terminal h See the operating instructions for length of charge information FOLLOW THESE STEPS WHEN THE BATTERY IS OUTSIDE THE VEHICLE A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY a Check the polarity of the battery post The POSITIVE POS P usually has a larger diameter than the NEGATIVE NEG N post b Attach at least a 24 inch long 6 gauge AWG insulated battery cable to the NEGATIVE NEG N battery post c Connect the POSITIVE RED charger clamp to the POSITIVE POS P post of the battery d Position yourself and free end of cable as far away from the battery as possible then connect the NEGATIVE BLACK charger clamp to the free end of cable e Do not face the battery when making the final connection f When disconnecting the charger always do so in reverse sequence of connecting procedure and break the first connection while stan
8. ding as far away from the battery as practical g 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 CONNECTION INSTRUCTIONS The charger should be grounded to reduce the risk of electric shock This charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances DANGER Never alter the AC cord or plug provided if it will not fit the outlet have a proper outlet installed by a qualified electrician Improper connection can result in a risk of an electric shock This battery charger is for use on a nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated in FIGURE A A temporary adapter which looks like the adapter illustrated in FIGURE C may be used to connect this plug to a two pole receptacle as shown in FIGURE B until a properly grounded outlet can be installed by a qualified electrician DANGER Before using an adapter as illustrated be certain GROUNDING METHODS that the center screw of the outlet plate is grounded The green GROUNDED colored rigid ear or lug extending from the adapter must be OUTLET ADAPTER connected to a properly grounded outlet make certain it is N ADAPTER grounded If necessary replace the origina
9. hes to the OFF position and removing the AC cord from the electric outlet Never allow the clamps to touch each other b Attach the DC clamps to the battery post and twist or rock back and forth several times to make a good connection This tends to keep the clamps from slipping off the terminals and helps to reduce the risk of sparking paoop FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY a Position the AC and DC cords to reduce the risk of damage by the hood door or moving engine parts b Stay clear of fan blades belts pulleys and other parts that can cause injury to persons c Check the polarity of the battery post The POSITIVE POS P battery post usually has a larger diameter than the NEGATIVE NEG N post d Determine which post of the battery is grounded connected to the chassis If the negative post is grounded to the chassis as in most vehicles see item e If the positive post is grounded to the chassis see item f e For negative grounded vehicles connect the POSITIVE RED clamp from the battery charger to the POSITIVE POS P ungrounded post of the battery Connect the NEGATIVE BLACK clamp to the vehicle chassis heavy gauge metal part of the frame or engine block away from the battery Do not connect to the carburetor fuel lines or sheet metal body parts f For positive grounde
10. hing protection Avoid touching eyes while working near battery d If battery acid contacts skin or clothing wash immediately with soap and water If acid enter eyes immediately flood eyes with running cold water for at least 10 minutes and get medical attention immediately NEVER smoke or allow a spark or flame in vicinity of the battery or engine 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 parts that may cause an explosion g 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 h Use this charger for charging a LEAD ACID battery only It is not intended to supply power to a low voltage electrical system other than in an automotive application Do not use this 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 I NEVER charge a frozen battery mo PREPARING TO CHARGE a If necessary to remove battery from 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 b Be sure the area around the battery is well ventilated while the battery is bei
11. ime would then be calculated j by dividing the 35 AH depleted from the battery by the ampere charge rate of the charger To allow for tapering of the charge 4 rate add 25 percent to the charge time OPERATING INSTRUCTIONS CHARGING BLINKING RED LIGHT Indicates possible weak battery CONTINUOUS RED LIGHT Indicates AC power is on CONTINUOUS GREEN LIGHT Indicates correct connection If when battery is connected the green light does not light check for proper polarity or poor connections If the battery voltage is below 4 volts the green light will not come on yi BLINKING GREEN LIGHT Indicates charge is complete charger in the float mode 5 CONTINUOUS YELLOW LIGHT Indicates charging bulk charge less than 80 charged z BLINKING YELLOW LIGHT Indicates finish charge greater than 80 charged FLASHING GREEN AND YELLOW LIGHTS Flooded batteries only Indicates deep discharge recovery process NOTES FOUR SECOND DELAY To avoid sparking the charger tests for correct polarity before applying current to the battery When connected properly the green light will come on for 4 seconds before the yellow light comes on DEEP DISCHARGE RECOVERY If the charger determines a battery is deeply discharged it will attempt to recover the battery with a program designed to enhance charge acceptance Because of the high voltage levels required for recovery this program is not included for sealed batteries OPERATING PROCEDURE
12. l outlet cover plate 2 S screw with a longer screw that will secure the adapter ear or lug to COVER OF GROUNDED CA the outlet cover plate and make ground connection to grounded OUTLET BOX outlet A GROUNDING NOTE USE OF AN ADAPTER IS NOT ALLOWED IN B MEANS CANADA IF A GROUNDING TYPE RECEPTACLE IS NOT AVAILABLE DO NOT USE THIS APPLIANCE UNTIL THE PROPER OUTLET IS INSTALLED BY A QUALIFIED ELECTRICIAN 20 21 CHARGE PERIOD 22 ASSEMBLY INSTRUCTIONS 1 Remove the screws from the back of the charger and attach the handle in an upright position with the screws provided Assemble the clamp bar to the handle with two screws 2 Remove the four screws on the bottom toward the front of the charger and attach the leg with the screws provided 3 Put one of the axle nuts on one side of the axle by tapping the nut on with a hammer Then slide the axle through one of the wheels and then through the hole in the charger until it comes out the other end Put the other wheel and axle nut on The approximate required time to bring a battery to full charge state depends upon the number of ampere hours AH depleted from the battery AH are determined by multiplying the number of hours times the number of Amps supplied by a battery to a load and normally indicated on the battery For example if a load was connected to a battery which drew 7 Amps for a period of 5 hours the battery will have supplied 35 AH The approximate recharge t
13. ng charged Gas can be forcefully blown away by using a piece of cardboard or other non metallic material as a fan c Clean the battery terminals Be careful to keep corrosion from coming in contact with eyes d Add distilled water in each cell until battery acid reaches level specified by the battery manufacturer This helps purge excessive gas from cells Do not overfill For a battery without cell caps carefully follow the manufacturer s recharging instructions e Study all battery manufacturer s specific precautions such as removing or not removing the cell caps while charging and the recommended rates of charge f Determine voltage of the battery by referring to the car owner s manual and make sure that the output voltage selector switch is set at the correct voltage If the charger has adjustable charge rate charge the battery initially at the lowest rate 15 16 17 18 19 CHARGER LOCATION Locate the charger as far away from the battery as the DC cables permit Never place the charger directly above the battery being charged gases from the battery will corrode and damage the charger Never allow battery acid to drop on the charger when reading the specific gravity or filling battery Do not operate the charger in a closed in area or restrict ventilation in any way Do not set a battery on top of the charger DC CONNECTION PRECAUTIONS a Connect and disconnect the DC output clamps only after setting the charger switc
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