Battery Charger User Manual PDF
Contents
1. away from battery 4 Do not connect the ground clamp to the carburetor fuel line or body sheet metal Positive Ground Connect negative charger cable clamp black to negative battery terminal e Connect positive charger cable clamp red to vehicle chassis heavy gauge metal part of frame or engine block away from battery 4 Do not connect the ground clamp to the carburetor fuel line or body sheet metal Safety Information Disconnecting Charger e Turn Length of Charge Timer to OFF e Disconnect power cord e Remove clamp from ground and e Remove clamp from battery terminal Battery Not in Vehicle Follow this procedure when charging battery out of vehicle e Identify battery terminal polarity Negative terminal may be marked NEG N or Positive terminal may be marked POS P or 4 The positive terminal is usually larger diameter than the negative terminal on battery with top terminals e Attach at least a 24 inch long 6 gauge AWG insulated battery cable to negative terminal When charging side terminal battery out of vehicle use side terminal adaptors Connect positive charger cable clamp red to positive battery terminal e Position yourself and free end of cable as far away from battery as possible then connect negative charger cable clamp black to free end of cable previously installed Do not face battery when making final connection Disconnecting Charger e Turn2. Crank engine 4 Cranking assist is provided for approximately 5 seconds followed by a 120 second cool down Although most starter motors can withstand cranking for 15 seconds the charger only provides cranking assist for 5 seconds before cool down is required 12 BC5500B Operating Instructions Maintenance AWARNING AAWARNING Unplug power cord from outlet before cleaning or maintaining charger Turning off controls will not reduce this risk Read understand and follow Safety Information in the front of this manual Clean the case using a mild detergent Do not allow liquid to drip into the case Do not remove the case to perform routine maintenance Worn parts can compromise safety and charger performance Replace parts as needed For service contact your sales representative Assembly Instructions Use the following instructions to properly assemble battery charger before use Figure 3 Assembly Diagram Power Cord and Cables Not Shown 1 Attach handle to charger with two screws provided 2 Attach crossbar to handle with two screws provided 3 Attach floor brackets to base with hex head screws provided 4 Slide wheel onto axle with hub toward charger then slide axle through charger base 5 Place remaining wheel on axle and tap retainer nuts onto axle 13 Operating Instructions BC5500B Parts List Description Part Number Rectifier Assembly eessen BC4200 2000R Transformer
3. Length of Charge Timer to OFF e Disconnect power cord e Remove clamp from negative cable and e Remove clamp from positive terminal 4 Always disconnect charger in reverse sequence of connecting procedure Stand as far away as possible and face away from the battery when disconnecting ground clamp from cable connection BC5500B Operating Instructions Use this section for information about using the BC5500B Super 550 Battery Charger correctly and safely The following are included Functional Description e Battery Charging e Maintenance e Cranking Assist e Assembly and e Parts List Functional Description The BC5500B Super 550 Battery Charger is a constant voltage taper rate charger The voltage across the battery remains nearly constant while the charge current decreases or tapers as the battery approaches full charge The following information describes control panel features of the charger Figure 2 Control Panel Operating Instructions BC5500B A Coarse Rate Range Switch Selects volts for charge Range settings are 6LO 6HI 12L0 or 12HI B Fine Rate Range Switch Selects volts for charge Range settings are LO 2REG 3 HYBRID or HI MAIN FREE C Ammeter Meter Displays amps 0 to 100 ADC flowing from charger into battery D Length of Charge Timer Selects charger power mode and charge duration with manual or automatic shut off f
4. battery charger leads clear of moving parts such as fan blades pulleys hood and doors Moving parts can cause injury Risk of burns Batteries can produce a short circuit current high enough to weld jewelry to metal Remove jewelry such as rings bracelets and watches before working near batteries Short circuits can cause injury Safety Information Charging Instructions Follow the information in this section to help ensure safety when connecting the charger cables to battery For additional information refer to Battery Charging Procedure Battery in Vehicle Use this information when charging battery in vehicle e Do not charge automotive batteries installed in boats Remove the battery and charge on shore Onboard charging requires equipment designed for marine use e Identify battery terminal polarity Negative terminal may be marked NEG N or Positive terminal may be marked POS P or 7 The positive terminal is usually larger diameter than the negative terminal on batteries with top terminals e Identify system ground Negative ground system has negative terminal connected to chassis This is the most common type Positive ground system has positive terminal connected to chassis Negative Ground e Connect positive charger cable clamp red to positive battery terminal e Connect negative charger cable clamp black to vehicle chassis heavy gauge metal part of frame or engine block
5. of the possibility of such damages The entire liability of Snap on for damages to Buyer resulting from or arising out of the performance or non performance of this Agreement or for any cause whatsoever and regardless of the form of action whether in contract or in tort including negligence or strict liability or any other legal theory shall not exceed the purchase price for the specific item s of Battery Charger found to be defective Buyer assumes full responsibility for the overall operating environment in which the Battery Charger is to function including without limitation temperature humidity corrosive elements and dust or other air contaminants For further information contact Your Snap on Dealer or Representative Snap on Tools Company 2801 80th Street Kenosha WI 53141 1410 1 800 786 6600 Copyright 1998 Snap on Tools Company 1999 Snap on Incorporated ZBC5500B Printed in U S A 6 99
6. 2L0 or 12HI 12 volt battery LO Charges at a low voltage Useful for extended charging or finish charging on any lead acid battery 2 REG Charges at a slightly increased voltage To be used for regular lead acid or conventional batteries 3 HYBRID Charges at a higher voltage Select this setting for batteries that use combinations of lead antimony on positive plates and calcium lead on negative plates Hybrid batteries use porous plates saturated with electrolyte and fiberglass plate separators These recombination batteries are sold under such brand names as Chloride s Torque Starter and GNB s Cathanode or HI MAINT FREE Charges at the highest voltage needed for the maintenance free battery types These are typically calcium grid type internal construction batteries such as the Delco Freedom batteries 3 Measure and record battery state of charge Specific gravity Open circuit voltage 4 State of charge is used in step 9 to determine charge time 4 Verify AC power cord is disconnected from outlet and Length of Charge Timer is set to OFF Operating Instructions BC5500B 5 Connect charger cables to battery and power cord to outlet For additional information refer to mportant Safety Instructions Charging Instructions Never alter AC cord or plug provided If it will not fit outlet have proper outlet installed by a qualified electrician e Read understand and fol
7. Assembly ceecee BC5500 8000R Fan Blade d a a E 2 1268 Fam MOIO a e a eas vealed 2 10166 1 DC Leads with Clamps essseeceseeeeeeeeeereee BC5500 200R DGC Circuit Breaker miserata trunore iura biana nani 2 15366 AC Circuit Breaker cccccccccccc ccc eeceeceeeeeeaeeeeeeeeaeees 2 10266 Ammeter wera a ashes Geeta teen lees aay 4 280 POWER COG a a a a toate aaaese 6 2821 Rotary Voltage Range Switch ccceeceeeeeeeeeeees 2 13659 Charge Timer cceceeeceeeeeeeceeeeeeeeaeeeeeeeaeeeeeeeaeeeees 2 14866 Knob Charge Timer or Voltage Range 008 8 8230 Handle with Hardware cccecceceeeeeeeeeeeees EAK0073K20A Includes handle crossbar and 6 screws Foot With 4 SCrEWS cccccecceceecceeceeeeeeeeeneeees EAK0073K23A Wheel Kithsicvnci ist near tlc ee ol a h EAK0073K25A Includes 2 wheels 2 push nuts and axle 14 BC5500B Operating Instructions Wiring Diagram Figure 4 Wiring Diagram BC5500B Super 550 Battery Charger A Fine Rate B Course Rate C Black D White E Yellow F Red G Blue H Green I Brown J Gray SAVE THESE INSTRUCTIONS Operating Instructions BC5500B Snap on Super 550 Battery Charger Limited Warranty Limited Warranty Snap on Tools Company warrants only to the original Buyer that under normal use care and service the Battery Charger shall be free from defects in material and workmanship for 1 year from t
8. NS Safety Information Battery Gases Charging Preparation and Charger Location AAWARNING AWARNING Risk of explosion Gases produced by a battery are highly explosive Wear safety goggles and protective clothing user and bystander e Use charger in an area having at least 4 air changes per hour Read understand and follow all instructions for charger battery vehicle and any equipment used near battery and charger e Do not obstruct vents on charger housing Do not smoke strike a match place metal tools on battery or cause a spark in the vicinity of the battery When removing battery cables remove ground cable first e Clean terminals before charging battery During cleaning keep airborne corrosion from eyes nose and mouth Use baking soda and water to neutralize acid and help eliminate airborne corrosion Never allow clamps on charger cables to touch each other Do not expose charger to rain snow or wet conditions Do not allow battery gasses or acid to contact charger cabinet Do not place charger directly above or below battery Fill battery to level specified by battery manufacturer using distilled water e Remove or do not remove cell caps while charging per manufacturer s instructions Make sure charger cable clamps make tight connections Battery explosion can cause injury Acid Burns WARNING Battery acid is highly corrosive sulfuric acid Wear safety goggles user an
9. SE SHALL APPLY AND ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY EXCLUDED The obligations of Snap on under this warranty are limited solely to the repair or at the option of Snap on replacement of or refund of the original purchase price for Battery Charger or parts which to the satisfaction of Snap on are determined to be defective and which are necessary in the judgment of Snap on to return the Battery Charger to good operating condition Repairs or replacements qualifying under this Warranty will be performed or made on regular business days during normal working hours of Snap on within a reasonable time following Buyer s request All requests for warranty service must be made during the stated warranty period Limitation of Liability In no event shall Snap on be liable to Buyer or anyone claiming through or against Buyer for any special indirect or consequential damages including without limitation lost profits revenues anticipated sales business opportunities or goodwill interruption of business or loss of business information resulting from or arising out of a negligence b any breach or non performance of this agreement or any duties obligations responsibilities representations or warranties hereunder c the delivery installation operation performance use or maintenance or non performance delay in or failure of the Battery Charger or services to be provided hereunder or d otherwise even if Snap on has been advised
10. Snap on BC5500B Super 550 Battery Charger User s Manual IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety and operating instructions for Snap on Super 550 Battery Charger model BC5500B Refer to this manual often for information on safe operation Product Number Description BC5500B Red battery charger BC5500BGY Grey battery charger BC5500BPC Black battery charger BC5500BPF Teal battery charger BC5500BPM Berry battery charger BC5500BPQ Yellow battery charger Read All Instructions Read understand and follow all safety messages and instructions in this manual and on the test equipment Safety messages in this section of the manual contain a signal word a three part message and in some instances an icon The signal word indicates the level of hazard in a situation e Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury to the operator or bystanders e Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or bystanders The three part message uses three different type styles to further define the potential hazard e Normal type states the hazard Bold type states how to avoid the hazard e Italic type states the possible consequences of not avoiding the hazard An icon when present gives a graphical description of the potential hazard SAVE THESE INSTRUCTIO
11. d bystander Wear protective gloves Make sure someone can hear you or is close enough to provide aid when working near battery Have plenty of fresh water and soap nearby If battery acid contacts skin clothing or eyes flush the exposed area with soap and water for 10 minutes Seek medical help e Do not touch eyes while working near battery Battery acid can burn eyes and skin Safety Information Grounding AC Power Cord Connections and General Charger Use WARNING WARNING Risk of electric shock and fire Before connecting power cord to outlet make sure controls are set to OFF Do not remove or bypass the grounding pin Do not operate charger with damaged cord or plug Replace cord or plug immediately Position power cord and charger cables away from the hood doors or hot moving engine parts where they could be damaged e Use extension cord only when absolutely necessary An extension cord up to 25 feet must be 18 AWG up to 50 feet must be 14 AWG up to 100 feet must be 12 AWG and up to 150 feet must be 10 AWG and extension cord plug and charger plug must have the same number size and shape of pins Unplug power cord using plug rather than cord when disconnecting charger from outlet e Charger power cord uses equipment grounding conductor and a grounding plug Plug only into a three prong 120 VAC outlet that is correctly installed and grounded in accordance with all ordinances and l
12. e hours 40 60 80 160 275 430 Reserve Capacity 60 90 100 500 700 900 Cold Cranking Amps 300 400 500 LENGTH OF CHARGE TABLE BATTERY CAPACITY CHARGE BEGINNING AMPS CHARGE RATE Small 0 25 45 30 30 25 25 20 25 50 30 20 20 15 15 10 50 75 15 10 10 10 5 5 Medium 0 25 70 50 45 40 35 30 25 50 45 30 25 20 20 20 50 75 25 15 15 15 10 10 Large 10 25 90 55 55 50 45 45 25 50 60 40 34 30 30 30 50 75 30 20 20 15 15 15 APPROXIMATE MINUTES OF CHARGE 15 30 45 60 75 90 Chart 1 Determining Length of Charge using State of Charge and Capacity 10 Set required charge time on Length of Charge Timer If charge time exceeds 120 minutes perform one of following Set Length of Charge Timer for any portion of total charge time Reset timer for remaining time when charge time ends Reset Length of Charge Timer at any time to extend amount of charge time until total time required is reached Set Length of Charge Timer to HOLD and manually turn charger off when required time is reached Charger does not turn off automatically Overcharging can damage battery 11 Periodically monitor state of charge to prevent overcharging especially near end of charge period Battery is completely charged when specific gravity and or charging voltage do not increase after two hours 11 Operating Instructions BC5500B Charging More than One Battery Cranking Assist Passenger vehicles and light trucks with diesel engines may use two batterie
13. he date of original invoice except as otherwise provided herein The transformer and rectifier warranty period is 5 years from the date of original invoice This Warranty does not cover and separate charges for parts labor and related expenses shall apply to any damage to malfunctioning inoperability or improper operation of the Battery Charger caused by resulting from or attributable to A abuse misuse or tampering B alteration modification or adjustment of the Battery Charger by other than authorized representatives of Snap on C repair or maintenance other than specified operator maintenance of the Battery Charger or related equipment attachments peripherals or optional features by other than authorized representatives of Snap on D improper or negligent use application operation care cleaning storage or handling E fire water wind lightning or other natural causes or F adverse environmental conditions including without limitation excessive heat moisture corrosive elements or dust or other air contaminants radio frequency interference electric power failure power line voltages beyond those specified for the Battery Charger unusual physical electrical or electro magnetic stress and or any other condition outside of environmental specifications of Snap on NO OTHER WARRANTIES EXPRESS IMPLIED OR STATUTORY INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPO
14. low Safety Information in front of this manual Set Length of Charge Timer to HOLD Observe DC AMPS Some reading should be evident If OK allow to stabilize for 5 minutes Recheck DC AMPS reading If not set Length of Charge Timer to OFF Determine reason for no reading Correct before proceeding Determine battery capacity Capacity is usually marked on battery and rated in Ampere Hours AH Reserve Capacity RC or Cold Cranking Amps CCA 4 Battery capacity is used in step 9 to determine charge time Determine charge time using Chart 1 4 A battery charged 25 or lower may easily freeze charge immediately Example A battery is determined to be medium capacity since its CCA rating is 405 and Reserve Capacity is 90 minutes Open circuit voltage test shows 12 1 volts indicating about a 50 charge Five minutes after the charger is powered up charging current is 20 amps Therefore battery should be charged for 60 to 90 minutes as shown on the chart 10 BC5500B Operating Instructions STATE OF CHARGE STATE OF CHARGE 100 75 50 25 DEAD 6 amp 12V Specific Gravity 1 260 1 225 1 185 1 140 1 110 12V Open Circuit Voltage 12 6 12 4 12 1 11 9 11 8 6 V_Open Circuit Voltage 6 3 6 2 6 1 6 0 5 9 BATTERY CAPACITY 6V Battery Voltage 12V SMALL MEDIUM LARGE Battery Capacity SMALL MEDIUM LARGE 100 155 200 Amper
15. ocal codes When using an adapter refer to Figure 1 Unplug power cord from outlet before cleaning or maintaining charger Turning off controls will not reduce this risk Do not operate charger after a sharp impact dropping or any other damage Do not disassemble charger Call Snap on Sun Representative for repairs Use only recommended attachments e Do not charge a frozen battery Do not overcharge a battery e Use charger only for lead acid automotive batteries and for automotive cranking assist using procedure in this manual Do not use charger for charging dry cell batteries Electric shock or fire can cause injury Safety Information Refer to Figure 1 Use the charger on a nominal 120 VAC circuit that has a grounding outlet that looks like B An adaptor can be used such as one like E to connect the plug to a two pole outlet like C until a properly grounded outlet can be installed by a qualified electrician ADANGER Figure 1 Outlet and Plug Configurations A Charger Power Cord Plug B Grounded Power Outlet C Ungrounded Power Outlet D Green Grounding Lug must be properly grounded E Grounding Adaptor If necessary replace original outlet cover plate screw with a longer screw that will secure adaptor ear or lug to outlet cover plate making ground connection to grounded outlet Thermal Burns AWARNING Risk of entanglement Keep yourself clothing and
16. s Heavy duty trucks special service vehicles some agricultural and industrial equipment may use two or more batteries Charge multiple batteries up to 12 volts Batteries may be charged in a group if e Wired in parallel with the positive terminal of one battery connected to the positive terminal of the remaining battery ies and the negative terminals connected to negative terminals 4 Charging time is twice as long for a group of batteries wired in parallel as a single battery e Wired in series with the positive terminal connected to negative terminal between batteries and the voltage of all batteries combined is 12 volts i e two 6 volt batteries 4 If one battery of a parallel or series group is charged and another is discharged isolate the battery ies and charge separately Use this procedure to help the battery crank the engine over in a vehicle with a discharged battery e Use only on batteries in good condition e Do not use if the battery has been discharged for a long period of time since it may be sulfated 1 Turn off all accessories and lights 2 Connect clamps to battery terminals For additional information refer to Safety Information Charging Instructions 3 Plug charger power cord into properly grounded 120 VAC outlet 4 Set Length of Charge Timer to HOLD 5 Charge battery for five minutes 4 Partially charging battery helps direct more power to starter motor during cranking assist 6
17. unctions e OFF electrically shuts off power to the charger Select before connecting or disconnecting power cord or any leads e HOLD powers charger until OFF is manually selected Select when desired charge time exceeds 120 minutes Charger does not turn off automatically when this function is selected e CHARGE TIME is number of minutes the charger operates before automatically shut off Charger shuts off automatically after number of minutes selected lapse when this function is selected Upto 120 minutes can be selected Increase or decrease charge time as needed by selecting new time 7 The charger automatically shuts off when the charge time reaches zero BC5500B Operating Instructions Battery en Procedure Perform visual inspection of battery ies before charging to help prevent personal injury and property damage Check the following conditions correcting defects and or replacing battery ies and components as required Cracked case Improper electrolyte level fill to level specified by battery manufacturer Frozen electrolyte or resulting damage Loose or corroded terminal cable connection Frayed or broken cables Loose or over tightened battery hold down Correct size and capacity for vehicle 2 Set the Coarse Rate or Fine Rate switch Determine battery voltage from vehicle owner s manual or battery instructions Use 6LO or 6HI 6 volt battery 1
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