Associated Equipment BCH7112 User's Manual
Contents
1. MODEL BCH7112 MAL OPERATOR S MANUAL TOOLS co 11 12 13 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for battery charger Model BCH7112 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 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 That the extension cord is properly wired and in good condition and c That wire in cord is proper size as follows Minimum recommended AWG wire size for various length extension cords used wi2. A temporary adapter which looks like the adapter illustrated in sketch C may be used to connect this plug to a two pole receptacle as shown in sketch B GROUNDING METHODS until a properly grounded outlet can be installed by a qualified AN OUTLET ADAPTER electrician DANGER Before using an adapter as illustrated be certain that the N G ADAPTER center screw of the outlet plate is grounded The green colored rigid ear or lug Ela EONO OV 2 extending from the adapter must be connected to a properly grounded outlet make CD ja OUTLET BOX certain it is grounded If necessary replace the original outlet cover plate screw CA B with a longer screw that will secure the adapter ear or lug to the outlet cover plate EAS and make ground connection to grounded outlet CHARGE PERIOD 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 s 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 time would then be calculated by dividing the 35 AH depleted from the battery by the charge rate of the charger To allow for tapering of the charge rate add 25 percent to the charge time POSSIBLE CHARGING PROBLEMS 1 TH
3. ERMAL OVERLOAD SWITCH CIRCUIT BREAKER STARTS CYCLING a A battery with shorted cells will cause the circuit breaker to cycle indefinitely This must not be allowed to continue b Reversed charger connections will also cause cycling to continue indefinitely This must not be allowed to continue c If a severely discharged battery is in otherwise good condition the cycling will stop in 15 to 20 minutes when the battery has developed voltage to allow a normal charging rate 2 THERE IS NO METER READING a Check the AC outlet or extension cord connections to be sure power is being supplied to the battery charger b Check the clamps and terminals for corrosion c Avery low reading may indicate a defective battery A badly sulfated battery a result of remaining discharged for a long period or in some cases a completely discharged battery may produce this effect If the charge rate does not increase after three or four hours have the battery checked 3 THE METER NEEDLE SWINGS TO THE EXTREME RIGHT SIDE OF THE METER a Check for reverse polarity connections b If the battery is severely discharged the charge meter needle may start to cycle up and down This will stop after 15 to 20 minutes c The battery may one or more shorted cells Cycling will start immediately and continue indefinitely If cycling has not stopped as outlined in b disconnect the charger AC power cord first and have the battery tested MAINTENANCE INSTRUCTIONS Th
4. ES Many diesel vehicles and service vehicles are eguipped with two batteries This is to provide the vehicle with greater starting power capacity 2 or longer reserve capacity to provide power for accessories These batteries are wired into a parallel circuit Because of this it will take twice as long to charge these batteries See section 21 CHARGE PERIOD If one battery is charged and the other discharged the discharged battery should be removed from the vehicle and checked When attaching the charger to this type of vehicle the charger should be attached to the battery which is wired closest to the starter This allows the charger to provide maximum starting power to the starter motor by minimizing the voltage drop in the engine cables 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 sketch A
5. e 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 14 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 ventila
6. everal 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 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 grounded vehicles connect the NEGATIVE BLACK clamp from the battery charger to the NEGATIVE NEG N ungrounded post of the battery Connect the POSITIVE RED clamp to the vehicle chassis or engine away from
7. is charger requires minimal maintenance As with any appliance or tool a few common sense rules will prolong the life of the battery charger ALWAYS BE SURE THE CHARGER IS UNPLUGGED BEFORE DOING ANY MAINTENANCE OR CLEANING 1 Store in a clean dry place 2 Coil up the cords when not in use 3 Clean the case and cords with a slightly damp cloth 4 Clean any corrosion from the clamps with a solution of water and backing soda 5 Examine the cords periodically for cracking or other damage and have them replaced if necessary MODEL BCH7112 LIMITED WARRANTY ASSOCIATED EQUIPMENT CORPORATION MAKES THIS LIMITED WARRANTY TO THE ORIGINAL PURCHASER AT RETAIL OF THIS PRODUCT THIS WARRANTY IS NOT TRANSFERABLE Associated Equipment Corporation warrants this battery charger for two years from 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 transportation and or mailing charges prepaid to ASSOCIATED EQUIPMENT CORPORATION 5110 BROWN AVE SAINT LOUIS MISSOURI 63115 This limited warranty is void if the product is misused subjected to careless handling or repaired by anyone other than the factory Associated Equipment Corporation makes no warranty other than this limited warranty and expressly excludes any implied warranty including any warran
8. tch Allows for selection of one of three different operations 1 12VOLT 2 AMP CHARGE Best for small batteries used in motorcycles garden tractors etc 2 12 VOLT 10 AMP CHARGE Charges all larger 12 volt batteries at 10 Amps Output will drop as charge builds and battery voltage increases 3 12 VOLT ENGINE START 12 volt electrical systems only On this setting the charger will provide up to 50 amps additional current to aid in engine starting Due to the very high currents involved the charger must be allowed to cool for two to three minutes after ten seconds of steady engine start cranking CHARGER OVERLOAD PROTECTION The BCH7112 battery charger is protected from power overload by two automatic heat sensing switches One is in the DC output circuit the other is built on the transformer The first will operate when a short circuit reverse connections or too long engine cranking overloads the charger The protector will open with a click sound and will close in a few seconds The seconds protector will operate when a prolonged overload due to a defective battery or other excessive load causes the transformer to overheat It will close after several minutes when the transformer cools DC CONNECTION PRECAUTIONS a Connect and disconnect the DC output clamps only after 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 s
9. ted 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 15 16 17 18 19 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 CHARGER LOCATION a 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 drip 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 o o 0 OPERATING INSTRUCTIONS CHARGER CONTROLS Charge Selector Swi
10. th this charger Length of Cord Feet 25 50 100 150 AWG Size 18 18 16 14 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 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 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 ey
11. 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 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 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 the 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 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 standing as far away from the battery as practical g Amarine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use VEHICLES WITH TWO BATTERI
12. ty for consequential damages THIS IS THE ONLY EXPRESS LIMITED WARRANTY AND ASSOCIATED EQUIPMENT CORPORATION NEITHER ASSUMES NOR AUTHORIZES ANYONE TO ASSUME OR MAKE ANY OBLIGATION TOWARD THE PRODUCT OTHER THAN THIS EXPRESS LIMITED WARRANTY ASSOCIATED EQUIPMENT CORPORATION MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE OF THIS PRODUCT AND EXPRESSLY EXCLUDES SUCH FROM THIS LIMITED WARRANTY SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LENGTH OF IMPLIED WARRANTY SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE w1918 FIG 1 FIG 2 FILENAME MTLOGO EPS PLUG PLT ASSOCIATED EQUIPMENT CORPORATION 5110 BROWN AVE ST LOUIS MISSOURI 63115 314 385 5178 027 0531 ILLUSTRATION LISTING DESCRIPTION MAC TOOLS LOGO GROUNDING ADAPTER Rev 2 94 027 0531
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