Schumacher 94080035, 00-99-000906, 00-99-000906-0109, INC-700A, Industrial User Manual

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Schumacher 94080035, 00-99-000906, 00-99-000906-0109, INC-700A, Industrial User Manual

Model INC-700A

Power Supply/Battery Charger

Voltage: 12

Amperage: 4, 20, 70

OWNER’S MANUAL

READ ENTIRE MANUAL BEFORE

USING THIS PRODUCT

00-99-000906/0109

Table of Contents

section

PAGES

IMPORTANT SAFETY INSTRUCTIONS

1

PERSONAL PRECAUTIONS

2

PREPARING TO CHARGE

2

CHARGER LOCATION

3

DC CONNECTION PRECAUTIONS

3

FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED

IN VEHICLE.

3

FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE

 

VEHICLE.

4

battery charging - ac connections

5

control panel

7

Operating instructions

9

calculating charge time

13

maintenance instructions

14

storage instructions

15

troubleshooting

15

Limited warranty

17

IMPORTANT: read and save this safety and instruction manual.

1.IMPORTANT SAFETY INSTRUCTIONS

1.1SAVE THESE INSTRUCTIONS – The INC-700A offers a wide range of features to accommodate the needs for home or light commercial use. This manual will show you how to use your charger safely and effectively. Please read, understand and follow these instructions and precautions carefully, as this manual contains important safety and operating instructions.

1.2WARNING: Pursuant to California Proposition 65, this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

1.3Do not expose charger to rain or snow.

1.4Use only recommended attachments. Use of an attachment not recommended or sold by Schumacher® Electric Corporation may result in a risk of fire, electric shock or injury to persons.

1.5To reduce the risk of damage to electric plug or cord, pull by the plug rather than the cord when disconnecting the charger.

1.6An 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:

That the pins on the plug of the extension cord are the same number, size and shape as those of the plug on the charger.

That the extension cord is properly wired and in good electrical condition.

That the wire size is large enough for the AC ampere rating of the charger. An extension cord up to 25 feet must be 12 AWG; up to 50 feet must be 10 AWG.

1.7Do not operate the charger with a damaged cord or plug; take it to a qualified service person. (Call customer service at: 1-800-621-5485.)

1.8Do no operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way; take it to a qualified service person. (Call customer service at: 1-800-621-5485.)

1.9Do not disassemble the charger; take it to a qualified service person when service or repair is required. Incorrect reassembly may result in a risk of fire or electric shock. (Call customer service at: 1-800-621-5485.)

1.10To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Simply turning off the controls will not reduce this risk.

WARNING – RISK OF EXPLOSIVE GASES.

WORKING IN THE 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 YOU FOLLOW THE INSTRUCTIONS EACH TIME

1

YOU USE THE CHARGER.

TO REDUCE THE RISK OF BATTERY EXPLOSION, FOLLOW THESE INSTRUCTIONS AND THOSE PUBLISHED BY THE BATTERY MANUFACTURER AND THE MANUFACTURER OF ANY EQUIPMENT YOU INTEND TO USE IN THE VICINITY OF THE BATTERY. REVIEW THE CAUTIONARY MARKINGS ON THESE PRODUCTS AND ON THE ENGINE.

2.PERSONAL PRECAUTIONS

2.1Consider having someone close enough by to come to your aid when you work near a lead-acid battery.

2.2Have plenty of fresh water and soap nearby in case battery acid contacts your skin, clothing or eyes.

2.3Wear complete eye and body protection, including safety goggles and protective clothing. Avoid touching your eyes while working near the battery.

2.4If battery acid contacts your skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood the eye with cold running water for at least 10 minutes and get medical attention right away.

2.5NEVER smoke or allow a spark or flame in the vicinity of a battery or engine.

2.6Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or other electrical part that may cause an explosion.

2.7Remove 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.

2.8Use this charger for charging a LEAD-ACID battery only. 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.

2.9NEVER charge a frozen battery.

2.10NEVER overcharge a battery.

3.PREPARING TO CHARGE

3.1If it is necessary to remove the battery from the vehicle to charge it, always remove the grounded terminal first. Make sure all of the accessories in the vehicle are off, to prevent arcing.

3.2Be sure the area around the battery is well ventilated while the battery is being charged.

3.3Clean the battery terminals before charging the battery. During cleaning, keep airborne corrosion from coming into contact with your eyes, nose and mouth. Use baking soda and water to neutralize battery acid and help

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eliminate airborne corrosion. Do not touch your eyes, nose or mouth.

3.4Add distilled water to each cell until the battery acid reaches the level specified by the battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve regulated lead-acid-batteries, carefully follow the manufacturer’s recharging instructions.

3.5Read, understand and follow all instructions for the charger, battery, vehicle and any equipment used near the battery and charger. Study all of the battery manufacturer’s specific precautions while charging and recommended rates of charge.

3.6Make sure that the charger cable clips make tight connections.

4.CHARGER LOCATION

4.1Locate the charger as far away from the battery as the DC cables permit.

4.2Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.

4.3Do not set the battery on top of the charger.

4.4Never allow battery acid to drip onto the charger when reading the electrolyte specific gravity or filling the battery.

4.5Do not operate the charger in a closed-in area or restrict the ventilation in any way.

5.DC CONNECTION PRECAUTIONS

5.1Connect and disconnect the DC output clips only after pressing the

START/STOP ( ) button to turn the output off and removing the AC plug from the electrical outlet. Never allow the clips to touch each other.

5.2Attach the clips to the battery and chassis, as indicated in steps 6.5, 6.6 and 7.2 through 7.4.

6.FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE.

A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

6.1Position the AC and DC cables to reduce the risk of damage by the hood, door and moving or hot engine parts.

6.2Stay clear of fan blades, belts, pulleys and other parts that can cause injury.

6.3Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter then the NEGATIVE (NEG, N, -) post.

6.4Determine 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 step 6.5. If the positive post is grounded to the chassis, see step 6.6.

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6.5For a negative-grounded vehicle, connect the POSITIVE (RED) clip from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect the NEGATIVE (BLACK) clip to the vehicle chassis or engine block away from the battery. Do not connect the clip to the carburetor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

6.6For a positive-grounded vehicle, connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery. Connect the POSITIVE (RED) clip to the vehicle chassis or engine block away from the battery. Do not connect the clip to the carburetor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

6.7 When disconnecting the charger, press the START/STOP ( ) button to turn the output off, disconnect the AC cord, remove the clip from the vehicle chassis and then remove the clip from the battery terminal.

6.8See CALCULATING CHARGE TIME for length of charge information.

7.FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE.

A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

7.1Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.

7.2Attach at least a 24-inch long 4 gauge (AWG) insulated battery cable to the NEGATIVE (NEG, N, -) battery post.

7.3Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) post of the battery.

7.4Position yourself and the free end of the cable you previously attached to the NEGATIVE (NEG, N, -) battery post as far away from the battery as possible – then connect the NEGATIVE (BLACK) charger clip to the free end of the cable.

7.5Do not face the battery when making the final connection.

7.6 When disconnecting the charger, press the START/STOP ( ) button to turn the output off, disconnect the AC cord, remove the clip from the cable attached to the negative battery terminal and then remove the clip from the positive battery terminal.

7.7A marine (boat) battery must be removed and charged on shore. To charge it onboard requires equipment specially designed for marine use.

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8.battery charging - ac connections

8.1This battery charger, with auto line voltage select function, is for use on nominal 120 volt and 240 volt circuits.

DANGER – Never alter AC cord or plug provided – if it does not fit the outlet, have proper outlet installed by a qualified electrician. Improper connection can result in a risk of an electric shock or fire.

8.2Recommended minimum AWG size for extension cords for battery chargers: An extension cord up to 25 feet must be 12 AWG; up to 50 feet must be 10 AWG and must have the proper 20 amp rated plug and receptacle as shown below.

8.3Grounding Methods

This charger must be properly grounded. Make sure the AC outlet you are plugging it into is properly grounded per local codes and regulations. If it is not, have one installed by a qualified service person. Do not remove or bypass the grounding pin on the plug or receptacle.

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8.4Assembly instructions

This charger can be operated on a stable surface either upright or lying down (brackets not installed). Rubber strips have been provided to help prevent scratching and denting of the channels. If you would like to permanently mount the charger, use the following instructions:

8.5Slide all 4 brackets (Item 1) into the track on the back, from the right side, as shown above. Make sure the set screws (Item 2) are unscrewed enough so they do not scratch the surface of the housing.

8.6Measure what you are mounting the charger to before deciding where to locate the brackets (add an additional ¼ to ½ inch). Use the ruler on the label (Item 3) to mount the brackets (Item 1) in the correct position (position each bracket an equal distance from the center of the charger). Note that the inches shown are for both bracket dimensions combined (meaning the dimensions are doubled), this is for easier reference. Make sure the ¼-28 set screws (Item 4) are unscrewed enough so the pointed end is almost flush with the bracket. Mount the brackets (Item 1) by tightening all 8 set screws (Item 2).

8.7Lift the charger by its handle and set it against your mounting location,

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tighten the set screws (Item 4) to secure the brackets (Item 1), starting with the top two brackets first.

9.control panel

CONNECTED (yellow) LED

The CONNECTED (yellow) LED will light when the battery is properly connected.

CHARGING (yellow) LED

When charging begins, the CHARGING (yellow) LED will light.

CHARGED (green) LED

The CHARGED (green) LED will light when the charger has gone into maintain mode.

“UP” and “DOWN” ( and ) Buttons

Use these buttons to select the amount of time or voltage depending on the display function selected.

Start/Stop ( ) Button

This is the start and stop button for all modes.

Digital Display

The Digital Display gives a digital indication of voltage, amperes or time, depending on the DISPLAY function chosen.

Display Button

Use this button to set the function of the digital display to one of the following:

VOLTS (Voltmeter)

The voltmeter indicates the voltage at the battery terminals. If the reading is less than 10.5-volts, the battery may be bad or the connection at the charger may be poor. If the reading is 10.5 volts to 12.7 volts the battery is low – recharge it. If the reading is 12.8 volts or more the battery is charged.

AMPS (Ammeter)

The Ammeter indicates the amount of current, measured in amps, that is being drawn by the battery ( 2 amps). For example, in a 20 amp charge rate a typical discharged battery will initially draw approximately 20 amps.

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As the battery continues to charge the current will taper down. At full charge, the battery may draw less than one amp.

NOTE: The 70 amp charge rate cycles between 20 amps and 70 amps during the charging process and the ammeter will show this. This is a normal condition.

TIME (Timer – Range: 10 min to 120 min)

Used only in manual mode, the main function of the timer is to prevent over charging while allowing a battery time to obtain a satisfactory charge. To properly set the timer you must know the size of the battery in ampere hours or reserve capacity in minutes and the state of charge. Often the state of charge is not known, this is one reason why the timer was limited to 2 hours. With the aid of a battery load tester the state of charge can be obtained within a few seconds. For example, the average size automotive battery at a 50% state of charge will require 1 to 1½ hours of charging at a 40 amp rate to reach the full charge state. For the same battery with the timer set to its maximum, 2 hours, over charging will occur, but not likely to cause harm to a battery that was otherwise in

good condition. When the charge state is not known, start out with a timer setting of one hour or less.

Hold: This position defeats the timer function, allowing for continuous operation. Use when you want to charge more than 2 hours. Be sure to monitor the charging procedure and stop it when the battery is charged. Not doing so may cause damage to your battery or may cause other personal property damage or personal injury

MODE Button

Use this button to select between the AUTOMATIC CHARGE, MANUAL CHARGE and FLASH REPROGRAM function. See Operating Instructions section for details of these functions.

Battery Type Button

Use this button to set the type of battery to be charged to STANDARD or GEL CELL.

Regular – Set button to STANDARD. This battery type is usually used in cars, trucks and motorcycles. These batteries have vent caps and are often marked “Low Maintenance” or “Maintenance-free”. This type of battery is designed to deliver quick bursts of energy (such as starting engines) and have a greater plate count. The plates will also be thinner and have somewhat different material composition. Regular batteries should not be used for deep cycle applications.

Deep-Cycle – Set button to STANDARD. Deep-cycle batteries are usually marked as “Deep-Cycle” or “Marine”. Deep-cycle batteries are usually larger than the other types. This type of battery has less instant energy but somewhat greater long-term energy delivery than regular batteries. Deep cycle batteries have thicker plates and can survive a number of discharge cycles.

AGM – Set button to STANDARD. The Absorbed Glass Matt construction

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allows the electrolyte to be suspended in close proximity with the plate’s active material. In theory, this enhances both the discharge and recharge efficiency. Actually, the AGM batteries are a variant of Sealed VRLA batteries. Popular usage high performance engine starting, power sports, deep cycle, solar and storage battery. AGM batteries are typically good deep cycle batteries and they deliver best life performance if recharged before the battery drops below the 50 percent discharge rate. If these AGM batteries are discharged to a rate of 100 percent the cycle life will be 300 plus cycles and this is true of most AGM batteries rated as deep cycle batteries.

GEL – Set button to GEL CELL. The Gel Cell is similar to the AGM style because the electrolyte is suspended, but different because technically the AGM battery is still considered to be a wet cell. The electrolyte in a GEL cell has a silica additive that causes it to set up or stiffen. The recharge voltages on this type of cell are lower than the other styles of lead acid battery. This is probably the most sensitive cell in terms of adverse reactions to over-voltage charging. Gel Batteries are best used in VERY DEEP cycle application and may last a bit longer in hot weather applications. If the incorrect battery charger is used on a Gel Cell battery, poor performance and premature failure is certain.

The Gel Cell and the AGM batteries are specialty batteries that typically cost twice as much as a premium wet cell. However they store very well and do not tend to sulfate or degrade as easily as a wet cell. There is little chance of a hydrogen gas explosion or corrosion when using these batteries; these are the safest lead acid batteries you can use. Gel Cell and some AGM batteries may require a special charging rate.

Charge Rate Button

Use this button to set the maximum charge rate to one of the following:

4A Charge Rate – Intended for charging small batteries such as those commonly used in garden tractors, snow mobiles and motorcycles.

20A and 70A Charge Rate – Use for charging automotive and marine batteries. Not intended for industrial applications.

10.Operating instructions

Charger Operation

NOTE: Once automatic charging or flash reprogramming has started, the buttons will not work until you turn off the output, with the exception of the

Start/Stop ( ) button. (In MANUAL mode the “UP” and “DOWN” ( and ) buttons also still operate normally.) When the display shows no buttons will work for five seconds as the charger automatically goes back

to the default settings.

Automatic Charging

1. Connect the battery and AC power following the precautions listed in sections 6, 7 and 8.

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2.Set the MODE to AUTOMATIC CHARGE.

3.Set the BATTERY TYPE to STANDARD or GEL CELL.

4.Set the CHARGE RATE to 4A, 20A or 70A.

5.Press the Start/Stop () button when you are ready to start charging.

6.The CHARGING (yellow) LED will light.

NOTE: Automatic charging starts only if the CONNECTED (yellow) LED is lit and the battery has at least a 1V charge. If the battery is less than 1V, press and hold the Start/Stop ( ) button for five seconds to start Automatic Charging, or charge it in Manual mode for five minutes then switch back to Automatic Charge.

7.The CHARGED (green) LED will light when charging is complete and the charger has gone into maintain mode.

Manual Charging

1.Connect the battery and AC power following the precautions listed in sections 6, 7 and 8.

2.Set the MODE to MANUAL CHARGE. (The TIME LED will start blinking.)

3.Use “UP” and “DOWN” ( and ) buttons to set the time (shown in minutes) you want the charger to charge the battery. Set to to run the charger without a time limit.

4.Set the BATTERY TYPE to STANDARD or GEL CELL.

5.Set the CHARGE RATE to 4A, 20A or 70A.

6.Press the Start/Stop () button when you are ready to start charging.

NOTE: Be sure to monitor the charging procedure and stop it when the battery is charged. Not doing so may cause damage to your battery or may cause other personal property damage or personal injury.

Charging

If the charger does not detect a properly connected battery, the CON-

NECTED (yellow) LED will not light until such a battery is detected. Charging will not begin while the CONNECTED (yellow) LED is not on. When charging begins, the CHARGING (yellow) LED will light.

Battery Percent and Charge Time

This charger adjusts the charging time in order to charge the battery completely, efficiently and safely. The microprocessor automatically performs the necessary functions. This section includes guidelines that can be used to estimate charging times.

The duration of the charging process depends on these factors:

Battery State – If a battery has only been slightly discharged, it can be charged in less than a few hours. The same battery could take up to 10 hours if very weak. The battery state can be estimated by

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using the built-in voltage tester. The lower the reading the longer charging will take.

Battery Rating – A higher rated battery will take longer to charge than a lower rated battery under the same conditions. A battery is rated in ampere hours (AH), reserve capacity (RC) and cold cranking amps (CCA). The lower the rating the quicker the battery will charge.

Charge Rate – The charge rate is measured in amps. This charger provides charge rates of 4A, 20A and 70A. The 4A rate is for charging smaller batteries such as those used for motorcycles and garden tractors. Such batteries should not be charged using the 20A or 70A rate. The 20A and 70A rates are for charging larger batteries. In the 20A and 70A mode, the charger begins at a low-charge rate and increases the charge rate if it is determined that the battery can accept the higher rate. All charging modes will decrease the charge current as the battery approaches maximum charge.

Automatic Charging Mode

When an automatic charge is performed, the charger switches to the maintain mode automatically after the battery is charged. For a battery with a starting voltage under 1 volt, press and hold the START/STOP

( ) button for five seconds to start Automatic Charging, or use manual mode to pre-charge the battery for five minutes, to get additional voltage into the battery for the charger to analyze.

Aborted Charge

If charging can not be completed normally, charging will abort. When charging aborts, the charger’s output is shut off, the CHARGING (yellow)

LED will go out and the digital display will display . The charger ignores all buttons except the START/STOP ( ) button in that state. Press the START/STOP () button to reset after an aborted charge.

Desulfation Mode

If the battery is left discharge for an extended period of time, it could become sulfated and not accept a normal charge. If the charger detects a sulfated battery, the charger will switch to a special mode of operation designed for such batteries. Activation of the special desulfation mode is indicated by the CHARGING (yellow) LED blinking. If successful, normal charging will resume after the battery is desulfated. The CHARGING

(yellow) LED will then stop blinking and stay lit. Desulfation could take up to 10 hours. If desulfation fails, charging will abort and the charger will go into abort mode.

Completion of Charge

Charge completion is indicated by the CHARGED (green) LED. When lit, the charger has stopped charging and switched to the Maintain Mode of operation. If you are charging a deep cycle battery, the CHARGED (green)

LED comes on when the battery is charged enough for normal use.

Maintain Mode

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