Atec BC-9400A User's Manual
Contents
1. 11 12 13 14 MODEL BC 9400A OPERATOR S MANUAL IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for 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 wet cell lead acid automotive type 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 a 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 Thatthe extension cord is properly wired and in good condition and c Ifthe length of the extension cord is less than 25 feet use a 16AWG cord If 50 feet 12AWG 100 feet 10A2. 90 100 se e s s 2 r a A obs 10 10 s s horca wire va fe ua ra hrer oroat varren os faez Jo ASSEMBLY INSTRUCTIONS Attach the handle to the charger using the four screws provided Attach the front leg to the base with the four hex head screw provided To attach wheels and axle to the base tap one axle nut onto the axle with a hammer slide one wheel onto the axle with the whitewall facing out place one washer onto the axle Push the axle through the base place washer and wheel on opposite side Tap axle nut onto the axle with a hammer OPERATING INSTRUCTIONS CAUTION This battery charger must be fully assembled before operating Failure to do so may result in risk of injury USE OF INSTRUMENT PANEL The MINUTES CHARGE timer has an OFF position a CONTINUOUS CHARGE position and a timed charge range from 0 to 90 minutes a OFF Always make sure the timer is in the OFF position before connecting or disconnecting the clamps from the battery The charger will not charge with the timer in this position b 0to 90 MINUTES TIMED CHARGE The timer will automatically turn the charger off at the end of the pre set charging time Turn the timer past 20 before setting the desired time c CONTINUOUS CHARGE This position is used for slow charging or parallel charging the timer will not shut the charger OFF while in this position Do not use this position for fast charging TO CHARGE BATTERIES Make the connections to the
3. NOTE SOME BATTERIES MAY BE SO BADLY SULFATED THEY CAN NOT BE RESTORED TO A NORMAL OPERATING CONDITION REGARDLESS OF THE RATE OF CHARGE OR THE LENGTH OF TIME THE CHARGE IS APPLIED IF THE BATTERY CANNOT BE RESTORED TO A FULLY CHARGED CONDITION BY A SLOW CHARGING IT SHOULD BE REPLACED WIRING DIAGRAM YELLDW TRANSFORMER MODEL BC 9400A PARTS LIST 610389 Timer 610392 Rectifier 610278 Amps Charge Meter 610277 Switch 610391 Transformer 610282 AC Cord 605671 Leg 610189 FanBlade 605677 DC Cable Set 610052 Axle w nuts 610190 Fan Motor 610283 Handle 605672 Wheels w nuts 610281 DC Circuit Breaker Parts may be purchased from your local authorized service depot listed in the Service Procedure manual supplied with your product If you elect to order parts from the factory you may do so by mail or phone Minimum order from the factory is 25 00 Orders received that are under the minimum will not be processed Taxes and freight are extra and are not considered to be part of the dollar value of the order We do not have a C O D policy Cashier check Money order Mastercard or VISA are acceptable If you use a Mastercard or VISA send only the number and expiration DO NOT SEND THE CARD MAINTENANCE INSTRUCTIONS Worn clamps and jaws should be replaced Worn parts can lead to poor connections and present a safety hazard See parts list for part number of jaw and clamp kits Any Maintenance or repair of this unit that involves disassembly of the c
4. and take appropriate action When the green light is on disconnect the POSITIVE RED clamp from the battery Attach the NEGATIVE BLACK clamp to the NEGATIVE NEG N ungrounded post of the battery Attach the POSITIVE RED clamp to the vehicle chassis or engine 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 h 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 i 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 BATTERY EXPLOSION TO REDUCE THE RISK OF A SPARK NEAR THE Ball a Read section STOP GO LITE INSTRUCTIONS before proceeding b Check the polarity of the battery post The POSITIVE POS P usually has a larger diameter than the NEGATIVE NEG N post c Attach at least a 24 inch long 6 gauge AWG insulated battery cable to the NEGATIVE NEG N battery post d Connect the POSITIVE RED charger clamp to the POSITIVE POS P post of the battery e Touch the contact button of the STOP GO LITE to the free end of the battery cable If the red light comes on reverse the connections to the battery and retest When the green light come on position yourself and the
5. battery per the instructions in the previous sections Determine if the battery is 6 or 12 volts and then set the CHARGE VOLTAGE switch to 6 CHARGE for a 6 volt battery or 12 CHARGE BOOST for a 12 volt battery Turn the timer on The Ammeter will show the amount of current delivered to the battery Length of charge should be per the above chart and instructions BOOST STARTING Turn off all lights and accessories in the stalled vehicle Connect the charger to battery per previous instructions Charge the battery for at least five minutes before attempting to start the vehicle Put the switch in the 12 CHARGE BOOST position Start the vehicle with the charger connected to the battery Follow the duty cycle on the unit NOTE Do not crank the engine more than 20 seconds in any five minute period excessive cranking may overheat and damage the starter If the vehicle fails to start while waiting for the starter to cool allow the charger to continue to charge the battery Turn the switch to OFF and remove the AC power cord from the electric outlet before disconnecting the DC clamps CHARGING SULFATED BATTERIES If your battery has sat in the discharged state for an extended period of time it can become SULFATED This usually is seen as a white deposit near the top of the battery The sulfate is formed when a battery with low water levels remains discharged for an extended time Sulfated batteries exhibit the characteristic of accepting no charge regar
6. clamps only after setting the charger switches 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 STOP GO LITE INSTRUCTIONS When used properly the STOP GO LITE will indicate whether clamp connections will be correct Connect the positive red clamp to the positive POS P battery post Touch the contact button of the negative black clamp to the other battery post Observe the L E D lights in the STOP GO LITE GREEN LIGHT The first connection is correct Make the second clamp connection per instructions RED LIGHT The first connection made with the positive clamp to the battery is incorrect Attach the positive clamp to the other battery post and retest RED AND GREEN LIGHT The battery charger is turned on Turn the charger OFF and retest NO LIGHT Check for a shorted or open battery Clean any corrosion from the clamp jaws and the battery post and retest If still no light use a voltmeter or other means to make certain you have properly identified the polarity of the battery post Then attach the clamps per instructions disregarding the STOP GO LITE FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE A SPARK NEAR THE BATTERY MAY CAUS
7. free end of the cable as far away from the battery as possible then connect the NEGATIVE BLACK charger clamp to the free end of cable f Do not face the battery when making the final connection g Whendisconnecting the charger always do so in reverse sequence of connecting procedure and break the first connection while standing as far away from the battery as practical h A marine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use f Ra 20 GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS 21 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
8. E A BATTERY EXPLOSION TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY a Read the section STOP GO LITE INSTRUCTIONS before proceeding b Position the AC and DC cords to reduce the risk of damage by the hood door or moving engine parts c Stay clear of fan blades belts pulleys and other parts that can cause injury to persons d Check the polarity of the battery post The POSITIVE POS P battery post usually has a larger diameter than the NEGATIVE NEG N post e 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 f For negative grounded vehicles connect the POSITIVE RED clamp from the battery charger to the POSITIVE POS P ungrounded post of the battery Touch the contact button of the STOP GO LITE to the NEGATIVE NEG N battery post Interpret the light and take appropriate action When the green light is on 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 g For positive grounded vehicles connect the POSITIVE RED clamp from the battery charger to the POSITIVE POS P battery post Touch the contact button of the STOP GO LITE to the NEGATIVE NEG N battery post Interpret the light
9. WG 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 unless you are qualified to work on electrical products If not take itto 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 form 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 ofthe 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 compl
10. abinet should be done only by a gualified serviceman Incorrect reassembly may result in a risk of electric shock when the unit is subseguently used NOTES W 22 Rev 027 0518 FIG NOT RON FILE NAME LOGO EPS STOP GO WPG EXT BAT WPG PLUG ENG PLT ENGLSTBL PLT 8400CAB TIF 8400WR e PLT 8400A ENGLISH MANUAL ILLUSTRATION LISTING 27 523E MAN DESCRIPTION ASSOCIATED LOGO STOP GO LITE ON BATTERY ENGLISH EXTERNAL BATTERY W LEAD EXTENSION GROUNDING ADAPTER ENGLISH CHARGE RATE TABLE ENGLISH 8400A CABINET 8400A WIRING DIAGRAM ENGLISH
11. ated while the battery is being 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 a05 DC CONNECTION PRECAUTIONS a Connect and disconnect the DC output
12. dless of the rate of charge The charging method is two staged The first stage of attempting to break down the sulfation to allow the battery to accept a charge must be closely watched to avoid excessive charge rates as the battery begins to charge and overheating The second stage is a slow charging to restore the battery to full charge READ AND FOLLOW ALL PRECAUTIONS AND WARNINGS IN YOUR INSTRUCTION MANUAL BEFORE ATTEMPTING TO CHARGE SULFATED BATTERIES FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PROPERTY DAMAGE OR SERIOUS PERSONAL INJURY OR DEATH To recharge a sulfated battery 1 Attach the battery clamps as described in the instruction manual 2 Always use the chargers lowest rate when turning the charger on Set the charger to the chargers highest rate for the voltage of the battery being charged CAUTION NEVER CHARGE A BATTERY AT VOLTAGES RATES ABOVE THAT OF THE BATTERY 3 The battery will show little or no amperage at the start of the charging process This will continue until the sulfation begins to break down CAUTION AS THE SULFATION BREAKS DOWN THE AMPERAGE MAY RAPIDLY RISE CONSTANT ATTENTION MUST BE OBSERVED TO PREVENT SERIOUS OVERHEATING OF THE BATTERY 4 Lower the charge rate to the lowest rate for the voltage of battery being charged 5 Charge the battery at this low rate until the electrolyte reaches the fully charged state as described in the tables in your instruction manual This may take as long as two or three days
13. ete eye protection and clothing 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 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 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 p 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 ventil
14. 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 colored rigid ear or lug extending from the adapter must S be connected to a properly grounded outlet make certain it is COVER OF GROUNDED S grounded If necessary replace the original outlet cover plate A screw with a longer screw that will secure the adapter ear or lug to the outlet cover plate and make ground connection to grounded outlet NOTE USE OF AN ADAPTER IS NOT ALLOWED IN CANADA IF A GROUNDING TYPE RECEPTACLE IS NOT AVAILABLE DO NOT USE THIS APPLIANCE UNTIL THE PROPER OUTLET IS INSTALLED BY A QUALIFIED ELECTRICIAN D ds LENGTH OF CHARGE a Test the battery for state of charge Do not charge if it is over 75 charged or the battery is determined to be defective b Set beginning amps charge rate for size of battery and state of charge per charts c Charge for length of time per charge d Discontinue charge when the specific gravity of electrolyte reaches 1 260 or above A temperature compensating hydrometer should be used for this reading Discontinue charge if the battery begins to gas excessively or when the temperature of the electrolyte reaches approximately 120EF Do not overcharge batteries Overcharging results in excessive water loss and eventual damage to the battery BATTERY SIZE MEDIUM n BATTERY SIZE ZCHARGE MINUTES Resevecopccity 60
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