Associated Equipment 9402 User Manual
MODEL 9402
OPERATOR'S MANUAL
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions for the battery charger you have
purchased. You may need to refer to these instructions at a later date.
2.
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.
3. Do not expose the charger to rain or snow if specifically warned on the unit not to do so.
4. 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.
5. To reduce the risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger.
6. Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.
7. An 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:
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 with this
charger:
8. Do not operate the charger with a damaged cord or plug, replace them immediately.
9. 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.
10. 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.
11. To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Turning off the
controls will not reduce this risk.
Length of Cord, Feet 25 50 100 150
AWG Size 18 18 16 14
WARNING - RISK OF EXPLOSIVE GASES
12.
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
13.
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 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.
e. 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 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.
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15. CHARGER LOCATION
a. Locate the charger as far away from the battery as the DC cables permit.
b. Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.
c. Never allow battery acid to drip on the charger when reading the specific gravity or filling battery,
d. Do not operate the charger in a closed-in area, or restrict ventilation in any way.
e. Do not set a battery on top of the charger.
16.
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 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.
FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE. A SPARK NEAR THE BATTERY
17.
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 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
18.
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.
e. 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. A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for
marine use.
19.
VEHICLES WITH TWO BATTERIES
Many diesel vehicles and service vehicles are equipped with two batteries. This is to provide the vehicle with greater starting power
capacity 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.
GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS
20.
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 qualified electrician.
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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.
21.
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.
OPERATING INSTRUCTIONS
This automatic battery charger is designed to charge 6 or 12 volt batteries of either conventional or maintenance-free construction. Rated
output current is 10 or 2 DC amps. The 2 ampere setting is better for charging small 12 volt batteries under 20 amp hour size used with
motorcycles, garden tractors, etc. DO NOT TRY TO CHARGE A 6 VOLT BATTERY ON THE 12 VOLT SETTING. When operating this
charger, carefully follow the instructions in sections 17 and 18. When all connections have been made and the charger is connected to AC
power, the meter on the charger will indicate the amount of DC amperes of charge being delivered to the battery. This charging rate will
taper off as the battery comes up to full charge. In automatic chargers the voltage is limited to a preset level to prevent overcharging. The
charge rate drops to a very low pulsating rate to maintain battery charge level. If current is drawn from the battery as in some type of
standby operation, the charger will automatically come on to compensate.
DEEP CYCLE CHARGING - [To charge deep cycle batteries, you must monitor the charging to insure the size battery you are charging
permits the voltage to increase to the preset trickle trip point of the control circuit.] If the battery becomes very warm (– 125EF) or appears
to be bubbling freely charging should be stopped.
POSSIBLE CHARGING PROBLEMS
1. THE METER INDICATOR NEEDLE SWINGS TO THE EXTREME RIGHT SIDE OF THE METER:
This battery charger has been equipped with an automatic reset circuit breaker. This protects the charger from temporary overload
conditions. A severely discharged battery, a battery with shorted cells, or reversed charger connections at the battery will cause this
protective device to operate.
Under these overload conditions, the circuit breaker will open, and when cooled down will reset automatically.
This cycling process can be identified by a clicking sound made during the opening and closing of the circuit breaker.
a. Check for reverse polarity connections.
b. If the battery is severely discharged, the charge meter needle will start to cycle up and down, and will stabilize after 15 or 20 minutes.
c. The battery may have 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.
2. THERE IS NO METER READING:
a. Check the switch position.
b. Check the connections to the battery. Be sure the polarity is correct (red clamp to positive). "Rock" the clamps to bite through any dirt
or corrosion. If in a vehicle, be sure the terminals on the battery are clean and tight.
c. Check the AC outlet or extension cord connections, to be sure power is being supplied to the battery charger.
d. One or more cells may be shorted. The thermal switch in the charger may cycle (click on and off).
MAINTENANCE INSTRUCTIONS
This 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 PERFORMING 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 baking soda.
5. Examine the cords periodically for cracking or other damage and have them replaced if necessary.
WARNING: All other service should be done by qualified personnel only.
6.
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NOTES:
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