Associated Equipment BCH7109A User's Manual
Contents
1. M Ar MODEL BCH7109A OPERATOR S MANUAL TOOLS 10 11 12 13 14 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 That the 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 12A2. 2 screws included in the hardware bag OPERATING INSTRUCTIONS CAUTION this battery charger must be fully assembled before operating Failure to do so may result in risk of injury USE OF THE 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 The timer will not shut the charger OFF while in this position Extended Charging can be done if the operator is knowledgeable in determining the proper rate and length of charge and monitors the charging process to prevent overcharging TO CHARGE BATTERIES Make the connections to the 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 12 LOW CHARGE for a 6 or 12 volt battery If higher rate is desired set at 12 MED or 12 HIGH DO NOT charge a 6 volt battery at setting other than 6 12 low Damage may occur to the battery Turn the timer on and the Ammeter will show the amount of current delivered to the battery Length of charge should be per t
3. EE ote n teeta Rare EET E a ton et Lake eects 605671 ACCOR siipien deo een thee tarred e EEA ate NA EE E 610696 Wheels wi nuts 2 0 00 0 eee eee 605672 Switch W knob 12 eee 605675 kandle Soa seit ase eas a ty stele pete GS a ate ad acetate 605213 DC Cable Set 0 cee eee eee 610855 Stop Go Lite a na eaaa iee i A A Gate Rete ys 604579 DC Circuit Breaker 1 0000 naana 610536 Fan Blade is dossi hacks paar d oats waned a ates es 610189 Axlew nutSirs wise ant owes doitswadiens a AARDE E aed 610052 Fan Motors ices t te Sion as ea et Vee dl ees 610190 Transformer see e Cae Re Ciena le ee ens Nae als ceed 610819 Rectifier or n eddie take aad aera ewes 610364 AC Br aker iva detain eaten ayer a ea dln 603597 Timer w knob 0 00 cette 610895 Clamp S detec octets ar a NAE a e tn hate adhe ahi aaa 6202 Amps Meter 2 25 6 sceicledebe die he ted de bees 605204 Jaw Kit repairs one clamp 0 00 e eee eee 610970 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
4. 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 Lower the charge rate to the lowest rate for the voltage of battery being charged 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 o gt 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 MODEL BCH7109A PARTS LIST Fronted corina
5. BATTERY MAY CAUSE 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 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
6. Interpret the light 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 o 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 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 com
7. WG 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 unless you are qualified to work on electrical products If not 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 ey
8. alled by a qualified electrician GROUNDING METHODS GROUNDED OUTLET ADAPTER ADAPTER oo COVER OF GROUNDED OUTLET BOX CC GROUNDING CAD B MEANS DANGER Before using an adapter as illustrated be certain that the center screw of the outlet plate is grounded The green colored rigid ear or lug extending from the adapter must be connected to a properly grounded outlet make certain it is grounded If necessary replace the original outlet cover plate 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 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 damag
9. e on 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 f Do not face the battery when making the final connection g 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 h Amarine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use 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 inst
10. e DC output 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
11. e to the battery ETT ei ERATE CHARGE RATE Vs MINUTES CHARGE BATTERY SIZE SMALL MEDIUM LARGE BATTERY SIZE CHARGE MINUTES Ampere Hours 4G GA B 5 30 45 60 75 op Reserve Capacity C g 100 5 25 4513813812525128 Cold Cranking Amps 275 ah ARG SMALL 25 50 A 34 28 28 15 15 10 50 75 M Jisji ji li s55 STATE OF CHARGE TABLE 25 P 7a sa 4s 4a 35 30 STATE OF CHARGE 75 SB 25 DEAD MEDIUM 25 56 E 45130 125 120120 120 Specific Gravity 1 225 1 185 1 14 1 118 50 75 i 25 15115 11 10118 Open Circuit Valtage 6 V 6 2 6 95 5 95 5 9 8 25 S 9 55 55 58 45 45 Open Circuit Voltage 12 V 12 4 12 1 11 9 11 8 LARGE 25 56 6G 4B 35 30 30 30 Open Circuit Voltage 24 V 24 8 24 2 23 8 23 6 50 75 30 20 20 15 15 15 ASSEMBLY INSTRUCTIONS 1 Remove the screws from the back of the charger and attach the handle in an upright position with the screws provided 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 on 4 Attach the clamp bar to the handle with two 10 16x1 1
12. ell ventilated 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 mo 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 papo DC CONNECTION PRECAUTIONS a Connect and disconnect th
13. es c Wear complete 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 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 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 w
14. he above chart and instructions 12 VOLT CRANKING ASSIST Turn off all lights and accessories in the stalled vehicle Connect the charger to battery per previous instructions Charge the battery on 12HI for at least five minutes before attempting to start the vehicle 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 regardless 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
15. 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 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 BCH7109A ENGLISH MANUAL ILLUSTRATION LISTING 27 600E MAN FIG FILE NAME DESCRIPTION 1 MTLOGO EPS MAC TOOLS LOGO 2 STOP GO WPG STOP GO LITE ON BATTERY ENGLISH 3 EXT BAT WPG EXTERNAL BATTERY W EXTENSION LEAD 4 PLUG ENG PLT GROUNDING ADAPTER ENGLISH 5 ENGLSTBL PLT CHARGE RATE TABLE ENGLISH 6 27 600A PLT BCH7109A CHARGER 7 6009B E PLT 6009 WIRING DIAGRAM ENGLISH Revision record 01 98 Add note 4 clamp bar attachment to assembly instructions Revise figure 6 graphic 27 600a plt to show clamp bar 06 01 Revise part list 610190 fan motor was 610696 610895 timer was 610555 610696 ac cord was 605206 610855 dc cable was 605207 610970 jaw kit was 6204
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